Handbook of High-Speed Machining Technology PDF
Preview Handbook of High-Speed Machining Technology
Handbook of High-speed Machining Technology OTHER OUTSTANDING VOLUMES IN THE CHAPMAN AND HALL ADVANCED INDUSTRIAL TECHNOLOGY SERIES V. Daniel Hunt: SMART ROBOTS: A Handbook of Intelligent Robotic Systems David F. Tver and Roger W. Bolz: ENCYCLOPEDIC DICTIONARY OF INDUS TRIAL TECHNOLOGY: Materials, Processes and Equipment Roger W. Bolz: MANUFACTURING AUTOMATION MANAGEMENT: A Pro ductivity Handbook Igor Aleksander: ARTIFICIAL VISION FOR ROBOTS D. J. Todd: WALKING MACHINES: An Introduction to Legged Robots Igor Aleksander: COMPUTING TECHNIQUES FOR ROBOTS Handbook of High-speed Machining Technology edited by Robert I. King NEW YORK LONDON CHAPMAN AND HALL This book is dedicated to Tom Vajda, whose inspiration and support in the early 1970s made high-speed machining as it is known today possible. Acknowledgments We, the authors, wish to give credit to those who have dedicated years of research to the subject of high-rate metal cutting theory, the long and under standing support of the United States Air Force Materials Laboratory, and the genius of Professor Carl J. Salomon, who developed the initial concepts. First published 1985 by Chapman and Hall 29 West 35th St., New York, N.Y. 10001 Published in Great Britain by Chapman and Hall Ltd 11 New Fetter Lane, London EC4P 4EE © 1985 Chapman and Hall Softcover reprint of the hardcover 1st edition 1985 All Rights Reserved. No part of this book may be reprinted, or reproduced or utilized in any form or by any electronic, mechanical or other means, now known or hereafter invented, including photocopying and recording, or in any information storage or retrieval system, without permission in writing from the publishers. Library of Congress Cataloging in Publication Data Main entry under title: Handbook of high speed machining technology. Includes bibliographies and index. 1. Metal-cutting-Handbooks, manuals, etc. I. King, Robert I. (Robert Ira), 1924- TJ1185.H16 1985 671.3'5 85-4113 ISBN-13: 978-1-4684-6423-8 e-ISBN-13: 978-1-4684-6421-4 001: 10.1007/978-1-4684-6421-4 Contents Dedication Acknowledgments Preface Part One General Theory 1 Historical Background 3 R. I. King 2 Cutting Theory and Chip Morphology 27 B. F. von Turkovich 3 Machine Dynamics 48 J. Tlusty 4 Cutting Fluids in Industry 154 C. F. Barth Part Two Turning C. F. Barth 5 Turning 173 Part Three Milling 6 General Theory and Its Application in the High-Speed Milling of Aluminum 197 T. Raj Aggarwal 7 Machine System Design and Performance 241 F. J. McGee 8 Operational Data 259 J. F. Truncale Part Four Drills and Drilling S.M.Wu 9 Introduction to Part Four 275 10 A Mathematical Model for Drill Point Geometry 277 11 Microcomputer-Controlled Seven Axis Drill Point Grinder 287 12 Drill Analyzer 296 vi Contents 13 Multifacet Drills 305 14 An End Effector for Robotic Drilling 317 Part Five Grinding R. S. Hahn 15 Grinding 329 Part Six Laser Applications S. M. Copley 16 Laser Applications 387 Part Seven General Management Considerations 17 General Management Considerations 419 W. V. Burgess 18 Factory Models 423 R. C. Stewart 19 Economic Models for Process Development 436 V. H. Tipnis 20 Quality Control Circles: The Key to Employee Performance Improvement 447 W. S. Rieker 21 Leadership: The "Right Stuff" for Management of Human Productivity 459 W. V. Burgess Index 468 Preface The United States now spends approximately $115 billion annually to perform its metal removal tasks using conventional machining technology. Of this total amount, about $14 billion is invested in the aerospace and associated industries. It becomes clear that metal removal technology is a very important candidate for rigorous investigation looking toward improvement of produc tivity within the manufacturing system. To aid in this endeavor, work has begun to establish a new scientific and technical base that will provide prin ciples upon which manufacturing decisions may be based. One of the metal removal areas that has the potential for great economic advantages is high-speed machining and related technology. This text is con cerned with discussions of ways in which high-speed machining systems can solve immediate problems of profiling, pocketing, slotting, sculpturing, facing, turning, drilling, and thin-walled sectioning. Benefits to many existing programs are provided by aiding in solving a current management production problem, that of efficiently removing large volumes of metal by chip removal. The injection of new high-rate metal removal techniques into conventional production procedures, which have remained basically unchanged for a cen tury, presents a formidable systems problem, both technically and man agerially.The proper solution requires a sophisticated, difficult process whereby management-worker relationships are reassessed, age-old machine deSigns reevaluated, and a new vista of product/process planning and design admitted. The key to maximum productivity is a "systems approach." The text was structured with this in mind, and the reader can gain the greatest benefit by using the various chapters as building blocks from which an overall production system can be synthesized. The "bottom line" is to increase the overall effectiveness of the factory from whatever source, that is, to obtain the greatest return on investment. Consider the technical problem of increasing the speed of the cutter through the base material by one magnitude. To realize the benefits of this increase, viii Preface the table feed must be increased to a compatible rate. This in tum requires lighter inertia tables, more powerful drive motors, and more responsive control systems. As the speed increases, new dynamic ranges are encountered that induce undesirable resonances in the machine and parts being fabricated, requiring additional dampening consideration. Concerning the cutter-material interface, the basic chip morphology changes as new cutting regimes are experienced; hence Taylors age-old empirical equations no longer hold, since they are not velocity dependent. Even the cutter configuration must now be considered a function of the cutting speed regime, as well as the normal process parameters. The proper incorporation of high-speed machining into factory processes requires the integration of all of the above technical con siderations plus many others-a difficult systems problem requiring profes sional attention. Part Seven, Management Considerations, is considered the "keystone" of the text and must complement the other parts. High-speed machining should be selectively applied, and only when it is economically justified. This manu facturing procedure is not a panacea for underproductive, high-cost operations; however, if it is used properly, when economics dictate, in a well-loaded and well-balanced factory, the results can be extremely gratifying. Finally, one must consider the management style required to motivate the employees to accept these new procedures. Keep in mind that the changes suggested in this text are drastic and deviate from practices that have existed for at least a century. Use of the new techniques would be ill advised if the employees are not supportive of them for any reason. Employee involvement and understanding are necessary for success, and fear of the unknown is unacceptable. I am reminded of an excerpt from The Prince (1513) by Niccolo Machiavelli: It must be considered that there is nothing more difficult to carry out, nor more doubtful of success, nor more dangerous to handle, than to initiate a new order of things. For the reformer has enemies in all those who profit by the old order, and only lukewarm defenders in all those who would profit by the new order, this lukewarmness arising partly from fear of their adversaries, who have the laws in their favour; and partly from the incredulity of mankind, who do not truly believe in anything new until they have had actual experience of it. Thus it arises that on every opportunity for attacking the reformer, his opponents do so with the zeal of partisans, the others only defend him half heartediy, so that between them he runs great dangers. February 1985 Robert 1. King San Jose, California Part One General Theory 1 CHAPTER Historical Background Robert I. King Lockheed Missiles and Space Company, Inc. Dr. Carl J. Salomon's Research The concept of high-speed machining was conceived by Dr. Carl J. Salomon during a series of experiments from 1924 to 1931. This is documented in German patent number 523594 dated 27 April 1931. The patent was based on a series of curves of cutting speeds plotted against generated cutting tem peratures. These experiments were performed on nonferrous metals such as aluminum, copper, and bronze. Salomon obtained speeds up to 54,200 surface feet per minute (sfm) [16,500 surface meters per minute (srrun)] using helical milling cutters on aluminum. His contention was that the cutting temperature reached a peak at a given cutting speed; however, as the cutting speed was further increased, the temperature decreased. Figure 1.1 is a simplistic presen tation of this concept. As the cutting speed is increased from 0 in the normal mode, V1, the tem perature will increase in a direct relationship until a peak value Tcr is achieved. The cutting speed at Tcr is commonly called the critical cutting speed, Vcr. If the cutting speed is further increased, it was predicted that the cutting tem perature would decline. On either side of Vcr' Salomon suggested that there was an unworkable regime in which cutters were not able to stand the severe process temperatures and forces. The shape of the curve was thought to be dependent on the exact nature of the base material being cut. When the cutting speed was sufficiently increased, the resulting temperatures were re duced to those of the normal cutting temperatures, and the materials and cut ters would once again permit practical cutting procedures. The same cutting
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