كتاب Metal Cutting

موضوع: كتاب Metal Cutting الجمعة 09 أغسطس 2013, 11:24 am

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Metal Cutting
Fourth Edition
Edward M. Trent

ويتناول الموضوعات الأتية :

Department of Metallurgy and Materials
University of Birmingham, England
Paul K. Wright
Department of Mechanical Engineering
University of California at Berkeley, U.S.
TABLE OF CONTENTS
Foreword ix
Preface xi
Acknowledgements xv
Chapter 1 Introduction: Historical and Economic Context 1
The Metal Cutting (or Machining) Process 1
A Short History of Machining 2
Machining and the Global Economy 4
Summary and Conclusion 7
References 8
Chapter 2 Metal Cutting Operations and Terminology 9
Introduction 9
Turning 9
Boring Operations 12
Drilling 13
Facing 14
Forming and Parting Off 14
Milling 14
Shaping and Planing 16
Broaching 18
Conclusion 19
References 19
Bibliography (Also see Chapter 15) 19
Chapter 3 The Essential Features of Metal Cutting 21
Introduction 21vi
The Chip 23
Techniques for Study of Chip Formation 24
Chip Shape 25
Chip Formation 26
The Chip/tool Interface 29
Chip Flow Under Conditions of Seizure 40
The Built-up Edge 41
Machined Surfaces 47
Summary and Conclusion 47
References 55
Chapter 4 Forces and Stresses in Metal Cutting 57
Introduction 57
Stress on the Shear Plane 58
Forces in the Flow Zone 60
The Shear Plane and Minimum Energy Theory 62
Forces in Cutting Metals and Alloys 74
Stresses in the Tool 79
Stress Distribution 80
Conclusion 95
References 95
Chapter 5 Heat in Metal Cutting 97
Introduction 97
Heat In the Primary Shear Zone 98
Heat at the Tool/work Interface 102
Heat Flow at the Tool Clearance Face 112
Heat in Areas of Sliding 113
Methods of Tool Temperature Measurement 114
Measured Temperature Distribution in Tools 121
Relationship of Tool Temperature to Speed 126
Relationship of Tool Temperature to Tool Design 128
Conclusion 130
References 130
Chapter 6 Cutting Tool Materials I: High Speed Steels 132
Introduction and Short History 132
Carbon Steel Tools 133
High Speed Steels 138
Structure and Composition 140
Properties of High Speed Steels 144
Tool Life and Performance of High Speed Steel Tools 149
Tool-life Testing 163
Conditions of Use 166vii
Further Development 167
Conclusion 173
References 173
Chapter 7 Cutting Tool Materials II: Cemented Carbides 175
Cemented Carbides: an Introduction 175
Structures and Properties 176
Tungsten Carbide-Cobalt Alloys (WC-Co) 177
Tool Life and Performance of Tungsten Carbide-Cobalt Tools 186
Tungsten-Titanium-Tantalum Carbide Bonded with Cobalt 202
Performance of (WC+TiC+TaC) -Co Tools 205
Perspective: “Straight” WC-Co Grades versus the “Steel-Cutting” Grades 209
Performance of “TiC Only” Based Tools 210
Performance of Laminated and Coated Tools 211
Practical Techniques of Using Cemented Carbides for Cutting 215
Conclusion on Carbide Tools 224
References 225
Chapter 8 Cutting Tool Materials III: Ceramics, CBN Diamond 227
Introduction 227
Alumina (Ceramic) Tools 227
Alumina-Based Composites (Al2O3 + TiC) 229
Sialon 231
Cubic Boron Nitride (CBN) 236
Diamond, Synthetic Diamond, and Diamond Coated Cutting Tools 239
General Survey of All Tool Materials 245
References 249
Chapter 9 Machinability 251
Introduction 251
Magnesium 252
Aluminum and Aluminum Alloys 254
Copper, Brass and Other Copper Alloys 258
Commercially Pure Iron 269
Steels: Alloy Steels and Heat-Treatments 269
Free-Cutting Steels 278
Austenitic Stainless Steels 290
Cast Iron 293
Nickel and Nickel Alloys 296
Titanium and Titanium Alloys 303
Zirconium 307
Conclusions on Machinability 307
References 309viii
Chapter 10 Coolants and Lubricants 311
Introduction 311
Coolants 313
Lubricants 322
Conclusions on Coolants and Lubricants 334
References 337
Chapter 11 High Speed Machining 339
Introduction to High Speed Machining 339
Economics of High Speed Machining 340
Brief Historical Perspective 341
Material Properties at High Strain Rates 343
Influence of Increasing Speed on Chip Formation 348
Stainless Steel 352
AISI 4340 359
Aerospace Aluminum and Titanium 360
Conclusions and Recommendations 363
References 368
Chapter 12 Modeling of Metal Cutting 371
Introduction to Modeling 371
Empirical Models 373
Review of Analytical Models 374
Mechanistic Models 375
Finite Element Analysis Based Models 382
Artificial Intelligence Based Modeling 397
Conclusions 404
References 406
Chapter 13 Management of Technology 411
Retrospective and Perspective 411
Conclusions on New Tool Materials 412
Conclusions on Machinability 414
Conclusions on Modeling 416
Machining and the Global Economy 417
References 422
Chapter 14 Exercises For Students 425
Review Questions 425
Interactive Further Work on the Shear Plane 434
Bibliography and Selected Web-sites 435
Index 43

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