CNC Machining Technology: Volume II Cutting, Fluids and Workholding Technologies PDF
Preview CNC Machining Technology: Volume II Cutting, Fluids and Workholding Technologies
CNC Machining Technology Volume II Cutting, Fluids and Workholding Technologies Graham T. Smith CNC Machining Technology Volume II Cutting, Fluids and Workholding Technologies With 85 Figures Springer-Verlag London Berlin Heidelberg New York Paris Tokyo Hong Kong Barcelona Budapest Graham T. Smith Technology Research Centre, Southampton Institute, City Campus, East Park Terrace, Southampton S09 4WW, UK Cover illustration: Ch.3, Fig.30. A computer "hardcopy" off the CADCAM system showing the multi-vice setup where the precise location of each part is known. [Courtesy of System 3R International.] ISBN -13: 978-3-540-19829-1 e-ISBN -13: 978-1-4471-2053-7 DOl: 10.1007/978-1-4471-2053-7 British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library Library of Congress Cataloging-in-Publication Data A catalog record for this book is available from the Library of Congress Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permitted under the Copyright, Designs and Patents Act 1988, this publication may only be reproduced, stored or transmitted, in any form or by any means, with the prior permission in writing of the publishers, or in the case of reprographic reproduction in accordance with the terms of licences issued by the Copyright Licensing Agency. Enquiries concerning reproduction outside those terms should be sent to the publishers. © Springer-Verlag London Limited 1993 The publisher makes no representation, express or implied, with regard to the accuracy of the information contained in this book and cannot accept any legal responsibility or liability for any errors or omissions that may be made. Typeset by Best-set Typesetter Ltd., Hong Kong 69/3830-543210 Printed on acid-free paper To my grandfather Mr T. W. Chandler who encouraged me to take an interest in all things EOf/JOE ANHP 0 EE IAIAE IIEIPAE AIAAEKOMENOE EOf/JOTATOE AE 0 EK THE TQN AAAQN Translation: A wise man learns from experience and an even wiser man from the experience of others PLATO 428-348 Be Contents 1 Cutting Tool Technology. . . . . . . . . . . . . . . . . . . . 1 1.1 Introduction............................. 1 1.2 Tooling - the Key to Prompt, Productive Operations. . 1 1.3 Basic Guidance in Determining a Toolings Set-up. . . . 2 1.4 Cutting Tool Materials. . . . . . . . . . . . . . . . . . . . . . 3 1.5 Insert Cutting Tool Geometries and their Selection . .. 13 1.6 Cutting Tool Diversity - a Review . . . . . . . . . . . . .. 25 1.7 Modular Quick-change Tooling. . . . . . . . . . . . . . .. 33 1.8 Tool and Workpiece MOnitoring Systems ......... 42 1.9 Tool Management. . . . . . . . . . . . . . . . . . . . . . . .. 56 2 Cutting Fluids . . . . . . . . . . . . . . . . . . . . . . . . . .. 67 2.1 Introduction............................. 67 2.2 Stock Removal Processes . . . . . . . . . . . . . . . . . . .. 67 2.3 Types of Cutting Fluids . . . . . . . . . . . . . . . . . . . .. 76 2.4 Choosing the Right Cutting Fluid. . . . . . . . . . . . . .. 87 2.5 Handling and Use of Cutting Fluids. . . . . . . . . . . .. 89 3 Workholding Technology . . . . . . . . . . . . . . . . . .. 97 3.1 Introduction............................. 97 3.2 Turning Centre Workholding Techniques . . . . . . . .. 100 3.3 Advanced Workholding Methods on Turning Centres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 116 3.4 Programmable Steadies - their Role in Workholding .. 118 3.5 Workpiece Delivery to "Stand-alone" Turning Centres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 119 3.6 Part-catchers ............................ 121 3.7 Machining Centre Workholding Techniques . . . . . .. 123 3.8 Workpiece Delivery Systems to Turning and Machining Centres ........................ 142 3.9 Computerised Workholding Techniques - the Philosophy behind the Applications. . . . . . . . . . . .. 149 viii Contents Appendix National and International Machine Tool Standards ......................... 153 Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . .. 154 Selected Bibliography . . . . . . . . . . . . . . . . . . . . . . . .. 177 Company Addresses. . . . . . . . . . . . . . . . . . . . . . . . . .. 179 Index ..................................... 187 Preface Each volume in this series of three attempts to explain the design of turning and machining centres and how they are operated through part programming languages. Furthermore, a discussion about how such stand-alone machine tools can be networked into flexible manufacturing systems is given along with the problems relating to such interfacing. These volumes were written as a companion book to the successful Advanced Machining - The Handbook of Cutting Technology published jointly by IPS and Springer Verlag in 1989. The individual volumes look at interrelated aspects of using turning and machining centres: Volume I considers the design, construction and building of turning and machining centres, then goes on to consider how these individual machine tools can be networked together pro viding the desired communication protocols for flexible manu facturing systems, leading to a complete Computerised Integrated Manufacturing system. This latter philosophy is discussed in terms of a case study on the most automated factory in Europe, ironically manufacturing turning and machining centres. Finally, mention is made of the efforts given to ensure significant advances in both ultra high-speed machining design and sub micron operation, which is sure to have a major impact on general turning and machining centres in the future. Volume II discusses the crucial point of ancillary activities associated with these machine tools, such as the cutting tool technology decisions that must be made in order to ensure that each machine is fully tooled-up and optimised efficiently. A brief review is also given on cutting tool materials development and tooling geometry considerations. Modular quick-change tooling is reviewed together with both tool and workpiece monitoring systems. A discussion follows on tool management, which becomes a major activity when a considerable tooling inventory exists within a manufacturing facility. Cutting fluids are an x Preface important comple~ment to cutting tools, as they not only extend tool life but additionally enhance the workpiece machined sur faces; therefore it is important to choose the correct cutting fluid and handle it in the approriate manner to obtain maximum benefit from its usage. Workholding technology is an expensive burden that requires careful consideration to achieve an economic optimisation, particularly in a larger scale automated facility such as in an F.M.S. environment and a range of workholding strategies and techniques are reviewed. Volume III is a highly focused text that discusses how a part program is generated - after a general discussion about con trollers. Consideration is given to the fundamentals of CNC programming and this becomes a major part of the volume with a structured development of how to build programs and where and when the "word address", "blueprint/conversational" and "parametric" programs are utilised. High speed machining fundamentals are considered along with the problems of servo lag and gain for both milling and turning operations. A section is devoted to "Reverse Engineering" using digitising/scanning techniques - allowing replicas to be used to generate part programs, as these techniques are becoming popular of late. Finally a discussion ensues on the design of CAD/CAM systems and how they might be used for multiple-axis machining, through a direct numerical control link. Graham T. Smith West End Southampton January 1993
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