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عدد المساهمات : 19002 التقييم : 35506 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
| موضوع: كتاب Metal Cutting Theory and Practice الإثنين 13 أبريل 2020, 12:38 am | |
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أخوانى فى الله أحضرت لكم كتاب Metal Cutting Theory and Practice Third Edition David A. Stephenson John S. Agapiou
و المحتوى كما يلي :
Contents Preface to the Third Edition xv Preface to the Second Edition xvii Preface to the First Edition .xix Authors xxi Chapter 1 Introduction 1 1.1 Scope of the Subject 1 1.2 Historical Development .1 1.2.1 Ancient and Medieval Predecessors 1 1.2.2 Canon Boring .4 1.2.3 The Industrial Revolution and the Steam Engine 7 1.2.4 Nineteenth-Century Quantity Production Industries . 10 1.2.5 Early Scientific Studies 15 1.2.6 Twentieth-Century Mass Production 17 1.2.7 Numerical Control 20 References 22 Chapter 2 Metal-Cutting Operations 27 2.1 Introduction .27 2.2 Turning 27 2.2.1 Hard Turning 29 2.3 Boring 30 2.4 Drilling 31 2.4.1 Deep-Hole Drilling 34 2.4.2 Microdrilling 37 2.5 Reaming .37 2.6 Milling .37 2.7 Planing and Shaping 44 2.8 Broaching 45 2.9 Tapping and Threading .46 2.10 Grinding and Related Abrasive Processes 56 2.11 Roller Burnishing 64 2.12 Deburring 65 2.13 Examples .66 2.14 Problems 78 References 80 Chapter 3 Machine Tools 83 3.1 Introduction .83 3.2 Production Machine Tools .83 3.3 CNC Machine Tools and CNC-Based Manufacturing Systems 88 3.3.1 General .88 3.3.2 Types of CNC Machines 89 3.3.3 CNC-Based Manufacturing Systems .99vi Contents 3.4 Machine Tool Structures . 108 3.5 Slides and Guideways 119 3.6 Axis Drives 122 3.7 Spindles . 127 3.8 Coolant Systems 141 3.9 Tool Changing Systems . 142 3.10 Pallets 145 3.11 Energy Use in CNC-Machining Centers . 146 3.12 Examples . 147 References 150 Chapter 4 Cutting Tools 159 4.1 Introduction . 159 4.2 Cutting-Tool Materials . 159 4.2.1 Introduction 159 4.2.2 Material Properties . 159 4.2.2.1 High-Speed Steel (HSS) and Related Materials . 163 4.2.2.2 Sintered Tungsten Carbide (WC) 164 4.2.2.3 Cermets . 166 4.2.2.4 Ceramics . 167 4.2.2.5 Polycrystalline Tools . 169 4.2.2.6 Polycrystalline Cubic Boron Nitride (PCBN) 170 4.2.2.7 Polycrystalline Diamond (PCD) . 171 4.3 Tool Coatings . 172 4.3.1 Coating Methods 172 4.3.2 Conventional Coating Materials . 174 4.3.3 Diamond and CBN Coatings 177 4.4 Basic Types of Cutting Tools . 178 4.5 Turning Tools . 179 4.5.1 Indexable Inserts 179 4.5.2 Groove Geometry (Chip Breaker) 183 4.5.3 Edge Preparations 183 4.5.4 Wiper Geometry . 185 4.5.5 Insert Clamping Methods . 185 4.5.6 Tool Angles 186 4.5.7 Thread Turning Tools . 187 4.5.8 Grooving and Cutoff Tools . 188 4.5.9 Form Tools . 189 4.6 Boring Tools 190 4.6.1 Single Point Boring Tools . 190 4.6.2 Multipoint Boring Tools . 196 4.7 Milling Tools . 196 4.7.1 Types of Milling Cutters 197 4.7.2 Cutter Design 200 4.7.3 Milling Inserts and Edge Clamping Methods 208 4.8 Drilling Tools 209 4.8.1 Twist Drill Structural Properties 211 4.8.2 Twist Drill Point Geometries . 214 4.8.3 Spade and Indexable Drills 223Contents vii 4.8.4 Subland and Step Drills 227 4.8.5 Multi-Tip (Deep Hole) Drills 228 4.8.6 Other Types of Drills 233 4.8.7 Chip Removal .234 4.8.8 Drill Life and Accuracy .237 4.8.9 Hole Deburring Tools . 239 4.9 Reamers .242 4.9.1 Types of Reamers .243 4.9.2 Reamer Geometry 244 4.10 Threading Tools .246 4.10.1 Taps 246 4.10.2 Thread Mills . 253 4.11 Grinding Wheels . 255 4.11.1 Abrasives 255 4.11.2 Bonds 257 4.11.3 Wheel Grades and Grit Sizes . 257 4.11.4 Operational Factors 259 4.12 Microsizing and Honing Tools 260 4.13 Burnishing Tools .263 4.14 Examples .263 4.15 Problems 274 References 275 Chapter 5 Toolholders and Workholders 281 5.1 Introduction . 281 5.2 Toolholding Systems . 281 5.2.1 General . 281 5.2.2 Modular and Quick-Change Toolholding Systems 284 5.3 Toolholder/Spindle Connections .290 5.3.1 General .290 5.3.2 Conventional Tapered “CAT-V” Connection .295 5.3.3 Face-Contact CAT-V Interfaces .303 5.3.4 HSK Interface .309 5.3.5 Proprietary Interfaces . 314 5.3.6 Quick-Change Interfaces (Toolholders/Adapters) 316 5.3.7 Toolholders for Turning Machines . 322 5.3.8 Evaluation and Comparison of Toolholder/Spindle Interface 323 5.4 Cutting Tool Clamping Systems 328 5.4.1 Milling Cutter Drives . 328 5.4.2 Side-Lock-Type Chucks 330 5.4.3 Collet Chucks . 331 5.4.4 Hydraulic Chucks . 336 5.4.5 Milling Chucks . 338 5.4.6 Shrink-Fit Chucks . 339 5.4.7 Proprietary Chucks . 341 5.4.8 Tapping Attachments .344 5.4.9 Reaming Attachments 345 5.4.10 Comparison of Cutting Tool Clamping Systems 345 5.5 Balancing Requirements for Toolholders 358viii Contents 5.6 Fixtures 362 5.6.1 General . 362 5.6.2 Types of Fixtures 364 5.6.3 Fixture Analysis . 370 5.7 Examples . 373 5.8 Problems 387 References 387 Chapter 6 Mechanics of Cutting . 393 6.1 Introduction . 393 6.2 Measurement of Cutting Forces and Chip Thickness . 393 6.3 Force Components . 395 6.4 Empirical Force Models 401 6.5 Specific Cutting Power 402 6.6 Chip Formation and Primary Plastic Deformation .404 6.7 Tool–Chip Friction and Secondary Deformation 412 6.8 Shear Plane and Slip-Line Theories for Continuous Chip Formation 416 6.9 Shear Plane Models for Oblique Cutting .420 6.10 Shear Zone Models 422 6.11 Minimum Work and Uniqueness Assumptions .425 6.12 Finite Element Models .426 6.13 Discontinuous Chip Formation . 431 6.14 Built-Up Edge Formation 434 6.15 Examples . 436 6.16 Problems 438 References 439 Chapter 7 Cutting Temperatures .449 7.1 Introduction .449 7.2 Measurement of Cutting Temperatures .449 7.2.1 Tool–Work Thermocouple Method and Related Techniques .449 7.2.2 Conventional Thermocouple Methods . 453 7.2.3 Metallurgical Methods . 454 7.2.4 Infrared Methods 454 7.2.5 Other Methods 456 7.3 Factors Affecting Cutting Temperatures . 456 7.4 Analytical Models for Steady-State Temperatures 457 7.5 Finite Element and Other Numerical Models .463 7.6 Temperatures in Interrupted Cutting .467 7.7 Temperatures in Drilling .469 7.8 Thermal Expansion . 471 7.9 Examples . 472 7.10 Problem 476 References 476 Chapter 8 Machining Process Analysis 483 8.1 Introduction .483 8.2 Turning 484 8.3 Boring 486Contents ix 8.4 Milling .487 8.4.1 Face Milling 489 8.4.2 End Milling .490 8.4.3 Ball End Milling 494 8.5 Drilling 494 8.6 Force Equations and Baseline Data .502 8.7 Process Simulation Application Examples 507 8.8 Finite Element Analysis for Clamping, Fixturing, and Workpiece Distortion Applications . 512 8.9 Finite Element Application Examples . 514 8.10 Examples . 519 8.11 Problems 524 References 525 Chapter 9 Tool Wear and Tool Life . 529 9.1 Introduction . 529 9.2 Types of Tool Wear 530 9.3 Measurement of Tool Wear . 537 9.4 Tool Wear Mechanisms . 538 9.5 Tool Wear: Material Considerations 541 9.6 Tool Life Testing 548 9.7 Tool Life Equations .549 9.8 Prediction of Tool Wear Rates . 551 9.9 Tool Fracture and Edge Chipping . 554 9.10 Drill Wear and Breakage . 556 9.11 Thermal Cracking and Tool Fracture in Milling 560 9.12 Tool Wear Monitoring . 561 9.13 Examples . 562 9.14 Problems 568 References 569 Chapter 10 Surface Finish, Integrity, and Flatness . 575 10.1 Introduction . 575 10.2 Measurement of Surface Finish . 576 10.2.1 Stylus Measurements . 576 10.2.2 Other Methods . 581 10.3 Surface Finish in Turning and Boring . 582 10.4 Surface Finish in Milling 586 10.5 Surface Finish in Drilling and Reaming .590 10.6 Surface Finish in Grinding 590 10.7 Residual Stresses in Machined Surfaces .592 10.8 White Layer Formation .594 10.9 Surface Burning in Grinding . 595 10.10 Measurement of Surface Flatness .597 10.11 Surface Flatness Compensation in Face Milling .599 10.11.1 Tool Path Direction Compensation .600 10.11.2 Depth of Cut Compensation 603 10.11.3 Tool Feed Compensation .605x Contents 10.11.4 Spindle-Part Tilt Compensation 606 10.11.5 Surface Flatness Compensation Methods Characteristics 608 10.12 Examples .609 10.13 Problems 618 References 618 Chapter 11 Machinability of Materials . 623 11.1 Introduction . 623 11.2 Machinability Criteria, Tests, and Indices 623 11.3 Chip Control 627 11.4 Burr Formation and Control 633 11.5 Machinability of Engineering Materials . 638 11.5.1 Magnesium Alloys . 638 11.5.2 Aluminum Alloys 640 11.5.3 Metal Matrix Composites 642 11.5.4 Copper Alloys 643 11.5.5 Cast Iron 644 11.5.6 Carbon and Low Alloy Steels .647 11.5.7 Stainless Steels 650 11.5.8 Powder Metal (P/M) Materials 652 11.5.9 Titanium Alloys . 653 11.5.10 Nickel Alloys .654 11.5.11 Depleted Uranium Alloys 656 References 657 Chapter 12 Machining Dynamics .665 12.1 Introduction .665 12.2 Vibration Analysis Methods 665 12.3 Vibration of Discrete (Lumped Mass) Systems .666 12.3.1 Single Degree-of-Freedom (SDOF) Systems 668 12.3.2 Multiple Degree-of-Freedom (MDOF) Systems . 673 12.4 Types of Machine Tool Vibration 678 12.5 Forced Vibration 680 12.6 Self-Excited Vibrations (Chatter) 683 12.6.1 Regenerative Chatter, Prediction of Stability Charts (Lobes) .684 12.6.2 Tlusty’s Theory 687 12.6.3 Shear Plane Method .694 12.6.4 Other Methods .695 12.6.5 Nonregenerative Chatter, Mode Coupling .698 12.7 Chatter Prediction 700 12.7.1 Experimental Machine Tool Vibration Analysis . 701 12.7.2 Measurement of Transfer Functions 702 12.8 Vibration Control .706 12.8.1 Stiffness Improvement .706 12.8.2 Isolation .707 12.8.3 Damping and Dynamic Absorption 707 12.8.4 Tool Design 709 12.8.5 Variation of Process Parameters 709Contents xi 12.9 Active Vibration Control . 710 12.10 Examples . 716 12.11 Problems 739 References 743 Chapter 13 Machining Economics and Optimization 751 13.1 Introduction . 751 13.2 Role of a Computerized Optimization System 753 13.3 Economic Considerations 755 13.4 Optimization of Machining Systems: Basic Factors . 756 13.5 Optimization of Machining Conditions 757 13.6 Formulation of the Optimization Problem 758 13.6.1 Formulation of Objective Function 758 13.6.2 Constraints 761 13.6.3 Problem Statement . 763 13.7 Optimization Techniques 764 13.7.1 Single-Pass Operation 764 13.7.2 Multipass Operation .764 13.7.3 Single-Station Multifunctional System (SSMS) . 765 13.7.4 Multistage Machining System 765 13.7.5 Cutting Tool Replacement Strategies . 766 13.7.6 Cutting Tool Strategies for Multifunctional Part Configurations . 767 13.8 Examples . 768 13.9 Problems 776 References 777 Chapter 14 Cutting Fluids . 783 14.1 Introduction . 783 14.2 Types of Cutting Fluids .784 14.2.1 Neat Oils .784 14.2.2 Water-Based Fluids 784 14.2.3 Gaseous Fluids . 786 14.2.4 Air–Oil Mists (Aerosols) 787 14.2.5 Cryogenic Fluids 788 14.3 Coolant Application 788 14.4 Filtering . 789 14.5 Condition Monitoring and Waste Treatment .794 14.6 Health and Safety Concerns 795 14.6.1 Toxicity .796 14.6.2 Dermatitis .796 14.6.3 Respiratory Disorders .796 14.6.4 Microbial Infections .796 14.6.5 Cancer 797 14.7 Dry and Near-Dry Machining Methods 797 14.8 Test Procedure for Cutting Fluid Evaluation . 798 References 798xii Contents Chapter 15 Minimum Quantity Lubrication .803 15.1 Introduction .803 15.2 MQL System Types .803 15.2.1 External and Internal Mist Delivery 804 15.2.2 One- and Two-Channel MQL Systems 805 15.3 MQL Oils .809 15.4 Machine Tools for MQL 810 15.5 MQL Cutting Tools . 812 15.6 Thermal Management and Dimensional Control 817 15.7 Air and Chip Handling 818 15.8 MQL Research Areas 819 15.8.1 Hard Alloy Machining and Grinding . 819 15.8.2 Alternative Carrying Gases and Cooling Strategies 820 15.8.3 MQL Process Modeling .820 15.8.4 Oil Additives and Ionic Fluids . 821 References 822 Chapter 16 Accuracy and Error Compensation of CNC Machining Systems 827 16.1 Introduction .827 16.2 Machine Tool Errors 828 16.3 Machine Tool Accuracy Characterization . 837 16.4 Machine Tool Performance Evaluation . 839 16.5 Method for Compensating the Dimensional Accuracy of CNC Machining System .865 16.5.1 Error Reduction and Compensation Strategies 865 16.5.2 Error Modeling Methods 872 16.5.3 Error Compensation Offset Methods .877 16.6 Examples .882 References 889 Chapter 17 Gear Machining .897 17.1 Introduction .897 17.2 Gear Types and Geometry .897 17.2.1 Gear Types .897 17.2.2 Gear Geometry and Accuracy Classes .898 17.3 Tooth Machining Methods for Parallel Axis Gears 900 17.3.1 Broaching . 901 17.3.2 Form Milling 904 17.3.3 Hobbing 905 17.3.4 Shaping .907 17.3.5 Form Grinding from the Solid .909 17.4 Bevel and Hypoid Gear Machining .909 17.4.1 Peripheral Milling 910 17.4.2 Face Milling . 912 17.4.3 Face Hobbing 913 17.5 Five-Axis Machining of Gears 914 17.5.1 Parallel Axis Gears 915 17.5.2 Bevel Gears 916Contents xiii 17.6 Gear Tooth Finishing Methods 917 17.6.1 Shaving . 917 17.6.2 Skiving (Hard Finishing) . 919 17.6.2.1 Skiving: Hard Recutting Processes 919 17.6.2.2 Skiving: Other Processes 920 17.6.3 Grinding .920 17.6.3.1 Form Grinding 921 17.6.3.2 Indexing Generating Grinding .922 17.6.3.3 Continuous Generating Grinding .923 17.6.4 Honing 924 17.6.5 Lapping .925 References 926 Index 933
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