Measurement in Machining and Tribology PDF
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Materials Forming, Machining and Tribology J. Paulo Davim Editor Measurement in Machining and Tribology Materials Forming, Machining and Tribology Series editor J. Paulo Davim, Aveiro, Portugal More information about this series at http://www.springer.com/series/11181 J. Paulo Davim Editor Measurement in Machining and Tribology 123 Editor J.PauloDavim Department ofMechanical Engineering University of Aveiro Aveiro, Portugal ISSN 2195-0911 ISSN 2195-092X (electronic) Materials Forming,Machining andTribology ISBN978-3-030-03821-2 ISBN978-3-030-03822-9 (eBook) https://doi.org/10.1007/978-3-030-03822-9 LibraryofCongressControlNumber:2018960757 ©SpringerNatureSwitzerlandAG2019 Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeorpart of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission orinformationstorageandretrieval,electronicadaptation,computersoftware,orbysimilarordissimilar methodologynowknownorhereafterdeveloped. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publicationdoesnotimply,evenintheabsenceofaspecificstatement,thatsuchnamesareexemptfrom therelevantprotectivelawsandregulationsandthereforefreeforgeneraluse. The publisher, the authors and the editors are safe to assume that the advice and information in this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authorsortheeditorsgiveawarranty,expressorimplied,withrespecttothematerialcontainedhereinor for any errors or omissions that may have been made. The publisher remains neutral with regard to jurisdictionalclaimsinpublishedmapsandinstitutionalaffiliations. ThisSpringerimprintispublishedbytheregisteredcompanySpringerNatureSwitzerlandAG Theregisteredcompanyaddressis:Gewerbestrasse11,6330Cham,Switzerland Preface Measurement is an essential part of modern science and engineering, but your definition it is not easy. In the classical definition, measurement is “the determi- nationorestimationofratiosofquantities”.Also,itiscurrentdefinemeasurement as“theassignmentofanumbertoacharacteristicofanobjectorevent,whichcan be compared with other objects or events”. The concept of measurement is dependent on the perspective and branch. Therefore, an improvement of the tech- nicalcapabilitytousetheconceptofmeasurementisveryimportantforthemodern industry. The purposeofthis book istopresentacollection ofchaptersexemplifying the aspectsofmeasurementinmachiningandtribology.Chapter1ofthebookprovides the importance of temperature in metal cutting and its proper measurement/ modelling.Chapter2isdedicatedtotheroleofoxygeninorthogonalmachiningof metals. Chapter 3 describes geometric accuracy of machine tools. Chapter 4 con- tains information onmachine visioninmeasurement. Finally, Chap.5 isdedicated to tribological measurement of electroless nickel coatings. This research book can be used as a book for final undergraduate engineering course or as a topic on measurement at the postgraduate level. Also, this book can serve as a useful reference for academics, researchers, manufacturing, mechanical, materials, industrial and production engineers, and professionals in industries. The interest of this book is great for many important institutes and universities as wellasindustries.So,itishopedthisbookwillinspireotherstoundertakeresearch in this field of machining and tribology. Finally,theeditoracknowledgesSpringerfortheprofessionalsupportandallthe chapter authors for their availability for this editorial project. Aveiro, Portugal J. Paulo Davim December 2018 v Contents 1 Importance of Temperature in Metal Cutting and Its Proper Measurement/Modeling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Viktor P. Astakhov and Jose Outeiro 2 The Role of Oxygen in Orthogonal Machining of Metals . . . . . . . . . 49 Pedro A. R. Rosa, Afonso V. L. Gregorio and J. Paulo Davim 3 Geometric Accuracy of Machine Tools . . . . . . . . . . . . . . . . . . . . . . . 89 Michal Holub 4 Machine Vision in Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 B. Suresh Kumar, V. Vijayan and J. Paulo Davim 5 Tribological Measurement of Electroless Nickel Coatings. . . . . . . . . 125 Prasanta Sahoo and Arkadeb Mukhopadhyay Index .... .... .... .... .... ..... .... .... .... .... .... ..... .... 153 vii About the Editor J. Paulo Davim received his Ph.D. in Mechanical Engineering in 1997, M.Sc. in Mechanical Engineering (materials and manufacturing processes) in 1991, Mechanical Engineering degree (5 years) in 1986, from the University of Porto (FEUP), the Aggregate title (Full Habilitation) from the University of Coimbra in 2005 and D.Sc. from London Metropolitan University in 2013. He is Eur Ing by FEANI, Brussels, and Senior Chartered Engineer by the Portuguese Institution of Engineers with an MBA and specialist title in Engineering and Industrial Management. Currently, he is Professor at the Department of Mechanical Engineering,UniversityofAveiro,Portugal.Hehasmorethan30yearsofteaching and research experiences in manufacturing, materials, mechanical and industrial engineering,withspecialemphasisinmachiningandtribology.Hehasalsointerest in management, engineering education and higher education for sustainability. He has guided large numbers of postdoc, Ph.D. and master’s students as well as has coordinated and participated in several financed research projects. He has received several scientific awards. He has worked as evaluator of projects for international research agencies as well as examiner of Ph.D. thesis for many universities in different countries. He is the editor in chief of several international journals, guest editor ofjournals, bookseditor,bookseries editor andScientificAdviser formany internationaljournalsandconferences.Presently,heisaneditorialboardmemberof 25 international journals andacts as reviewer for more than 80 prestigiousWebof Science journals. In addition, he has also published as editor (and co-editor) more than100booksandasauthor(andco-author)morethan10books,80chaptersand 400articlesinjournalsandconferences(morethan200articlesinjournalsindexed in Web of Science core collection/h-index 47+/6500+ citations and SCOPUS/ h-index 55+/9000+ citations). ix Chapter 1 Importance of Temperature in Metal Cutting and Its Proper Measurement/ Modeling Viktor P. Astakhov and Jose Outeiro Abstract This chapter reveals the modern objective of metal cutting processes as increased productivity of multiple machining operations. It is discussed that the only feasible option to increase productivity is increasing the cutting speed. The chapter further analyzed the known attempt to increase the cutting speed showing that the cutting temperature is the major constraint in such an endeavor. It is explained the notion of the optimal cutting temperature explaining that its wide acceptance is limited by lack of a physical explanation of its nature. The physical essence of the optimal cutting temperature is revealed. The place where the tem- perature in metal cutting should be measured is explained. The basic methods of measuring temperatures in metal cutting are discussed. Infrared measuring technology is explained in details including its physical principle, advantages and limitations, and use of very short-wave cameras. 1.1 Introduction 1.1.1 Modern Objective of Machining Reduction of direct manufacturing costs associated with machining operations is a never-ending challenge for manufacturing plants that have this problem more pressinginrecentyearsbecausetwoofprimereasons.Thefirstoneistheincreased use of special alloys with advanced properties and significant tightening of quality requirements for machined parts. The second one is increasing global competition which is changing the environment facing most companies today. Previously V.P.Astakhov(&) GeneralMotorsBusinessUnitofPSMi,1792,ElkLn,Okemos,MI48864,USA e-mail:[email protected] J.Outeiro LaBoMaP,ArtsetMetiersParisTech,RuePortedeParis,71250Cluny,France e-mail:[email protected] ©SpringerNatureSwitzerlandAG2019 1 J.PauloDavim(ed.),MeasurementinMachiningandTribology,MaterialsForming, MachiningandTribology,https://doi.org/10.1007/978-3-030-03822-9_1 2 V.P.AstakhovandJ.Outeiro sheltered from the global market, many manufacturing companies now concern how to hold and even increase profitability against international competitors. To meet these challenges, many metal-machining manufacturing companies strive to reduce cycle times and costs-per-parts/units through investing heavily in the increased use of high-speed high-efficiently machining operations and thus changing the whole metal-machining culture which was around for more than a hundred years. These changes include the utilization of machines with powerful digitally controlled truly high-speed motor spindles; the application of high-pressure through-tool metal-working fluid (hereafter MWF) supply; the implementation of high-precision hydraulic, shrink fit, and steerable tool holders; the integration of advanced cutting process monitoring; wider use of advanced cutting tool materials, and so on [1]. These changes can be called the fourth “silent” industrial revolution as they happened in rather short period of time [2] currently becoming well known as Industry 4.0 initiative. The implementation of the listed developments led to a stunning result: For the first time in the manufacturing history, the machining operatingtimebecameabottleneckinthepartmachiningcycletime.Inshopswith stand-alone CNC machines, the machining time is 20% of the operating time, whereasinautomotiveshopsthistimereaches60%.Thelatterisduetoaggressive toolusestrategy,eliminationofanytool/part inspectioninthemachine, adjustable pre-setting of the MWF pressure for each individual tool, automated (robotic) workpiece/part loading/unloading,usingtoolswithRFIDchips,andsoon.Inboth case, however, the actual machining time is the largest (commonly called as a bottleneck). Knowing these data, one should realize that the implementation of high-penetration rate tools and well-designed machining operations to reduce machining time has becoming a vital necessity. Unfortunately, some management level authorities of metal-machining companies misinterpreted the essence of the above-presented data and thus their multiple implications. In the authors’ opinion, this is because of management deal with the data presented in the cost format as shown in Fig. 1.1. Even if the direct manufacturing cost is considered, the cutting tool cost hardly exists 6%. These pictures/numbers blind “effective managers” as they look at the data presented as the driving force to send manufacturing opera- tions overseas countries where the labor cost is 5%. Moreover, it implies not to investinthedevelopmentofnewcuttingtools/advancedcuttingprocesses—whatto bother with 3% of costs. In the authors’ opinion, this is the major disconnect in modern machining world. Such a management perception stems from pre-fourth industrial revolution experience when the machining time in a cycle time of manufacturing part was so insignificant due to manual part loading–unloading, part and tool setting on the machine, part gaging in the machine, etc., took most of this time. As a result, a reduction of the machining operating time due to the use of advanced (and thus more expensive) cutting tools and optimization of machining processes was not requested and, therefore, discouraged as manufacturing professionals did not see any benefits of such activities. As a result, a number of “atavisms” are still in full
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