Geometry of Single-point Turning Tools and Drills: Fundamentals and Practical Applications (Springer Series in Advanced Manufacturing)

Geometry of Single-Point Turning Tools and Drills outlines clear objectives of cutting tool geometry selection and optimization, using multiple examples to provide a thorough explanation. It addresses several urgent problems that many present-day tool manufacturers, tool application specialists, and tool users, are facing. It is both a practical guide, offering useful, practical suggestions for the solution of common problems, and a useful reference on the most important aspects of cutting tool design, application, and troubleshooting practices. Covering emerging trends in cutting tool design, cutting tool geometry, machining regimes, and optimization of machining operations, Geometry of Single-Point Turning Tools and Drills is an indispensable source of information for tool designers, manufacturing engineers, research workers, and students. Preface Contents 1 What Does It Mean “Metal Cutting”? 1.1 Introduction 1.2 Known Results and Comparison with Other Forming Processes 1.2.1 Single-shear Plane Model of Metal Cutting 1.2.2 Metal Cutting vs. Other Closely Related Manufacturing Operations 1.3 What Went Wrong in the Representation of Metal Cutting? 1.3.1 Force Diagram 1.3.2 Resistance of the Work Material in Cutting 1.3.3 Comparison of the Known Solutions for the Single-shear Plane Model with Experimental Results 1.4 What is Metal Cutting? 1.4.1 Importance to Know the Right Answer 1.4.2 Definition 1.4.3 Relevance to the Cutting Tool Geometry 1.5 Fundamental Laws of Metal Cutting 1.5.1 Optimal Cutting Temperature – Makarow’s Law 1.5.2 Deformation Law References 2 Basic Definitions and Cutting Tool Geometry, Single Point Cutting Tools 2.1 Basic Terms and Definitions 2.1.1 Workpiece Surfaces 2.1.2 Tool Surfaces and Elements 2.1.3 Tool and Workpiece Motions 2.1.4 Types of Cutting 2.2 Cutting Tool Geometry Standards 2.3 Systems of Consideration of Tool Geometry 2.4 Tool-in-hand System (T-hand-S) 2.4.1 Tool-in-hand Coordinate System 2.4.2 References Planes 2.4.3 Tool Angles 2.4.4 Geometry of Cutting Tools with Indexable Inserts 2.5 Tool-in-machine System (T-mach-S) 2.5.1 Angles 2.5.2 Example 2.3 2.6 Tool-in-use System (T-use-S) 2.6.1 Reference Planes 2.6.2 The Concept 2.6.3 Modification of the T-hand-S Tool Geometry 2.6.4 Kinematic Angles 2.6.5 Example 2.4 2.7 Avalanched Representation of the Cutting Tool Geometry in T-hand-S 2.7.1 Basic Tool Geometry 2.7.2 Determination of Cutting Tool Angles Relation for a Wiper Cutting Insert 2.7.3 Determination of Cutting Tool Angles for a Single-point Tool 2.7.4 Flank Angles of a Dovetail Forming Tool 2.7.5 Summation of Several Motions References 3 Fundamentals of the Selection of Cutting Tool Geometry Parameters 3.1 Introduction 3.2 General Considerations in the Selection of the Parameters of Cutting Tool Geometry 3.2.1 Known Results 3.2.2 Ideal Tool Geometry and Constrains 3.2.3 Practical Gage for Experimental Evaluation of Tool Geometry 3.3 Tool Cutting Edge Angles 3.3.1 General Consideration 3.3.2 Uncut Chip Thickness in Non-free Cutting 3.3.3 Influence on the Surface Finish 3.3.4 Tools with κr > 90° 3.3.5 Tool Minor Cutting Edge Angle 3.4 Edge Preparation 3.4.1 General 3.4.2 Shape and Extent 3.4.3 Limitations 3.4.4 What Edge Preparation Actually Does 3.5 Rake Angle 3.5.1 Introduction 3.5.2 Influence on Plastic Deformation and Generalisations 3.5.3 Effective Rake Angle 3.5.4 Conditions for Using High Rake Angles 3.6 Flank Angle 3.7 Inclination Angle 3.7.1 Turning with Rotary Tools 3.7.2 Helical Treading Taps and Broaches 3.7.3 Milling Tools References 4 Straight Flute and Twist Drills 4.1 Introduction 4.2 Classification 4.3 Basic Terms 4.4 System Approach 4.4.1 System Objective 4.4.2 Understanding the Drilling System 4.4.3 Understanding the Tool 4.5 Force System Constrains on the Drill Penetration Rate 4.5.1 Force-balance Problem in Conventional Drills 4.5.2 Constraints on the Drill Penetration Rate 4.5.3 Drilling Torque 4.5.4 Axial Force 4.5.5 Axial Force (Thrust)-Torque Coupling 4.6 Drill Point 4.6.1 Basic Classifications 4.6.2 Tool Geometry Measures to Increase the Allowable Penetration Rate 4.7 Common Design and Manufacturing Flaws 4.7.1 Web Eccentricity/ Lip Index Error 4.7.2 Poor Surface Finish and Improper Tool Material/Hardness 4.7.3 Coolant Hole Location and Size 4.8 Tool Geometry 4.8.1 Straight-flute and Twist Drills Particularities 4.8.2 Geometry of the Typical Drill Point 4.8.3 Rake Angle 4.8.4 Inclination Angle 4.8.5 Flank Angle 4.8.6 Geometry of a Cutting Edge Located at an Angle to the y0-axis 4.8.7 Chisel Edge 4.8.8 Drill Flank is Formed by Two Planes: Generalization 4.8.9 Drill Flank Angle Formed by Three Planes 4.8.10 Flank Formed by Quadratic Surfaces 4.9 Load Over the Drill Cutting Edge 4.9.1 Uncut Chip Thickness in Drilling 4.9.2 Load Distribution Over the Cutting Edge 4.10 Drills with Curved and Segmented Cutting Edges 4.10.1 Load of the Cutting Part of a Drill with Curved Cutting Edges 4.10.2 Rake Angle References 5 Deep-hole Tools 5.1 Introduction 5.2 Generic Classification of Deep-hole Machining Operations 5.3 What does ‘Self-piloting Tool’ Mean? 5.3.1 Force Balance in Self-piloting Tools 5.4 Three Basic Kinematic Schemes of Drilling 5.4.1 Gundrill Rotates and the Workpiece is Stationary 5.4.2 Workpiece Rotates and the Gundrill is Stationary 5.4.3 Counterrotation 5.5 System Approach 5.5.1 Handling Tool Failure 5.5.2 System Considerations 5.6 Gundrills 5.6.1 Basic Geometry 5.6.2 Rake Surface 5.6.3 Geometry of Major Flanks 5.6.4 System Considerations in Gundrill Design 5.6.5 Examplification of Significance of the High MWF Pressure in the Bottom Clearance Space 5.6.6 Example of Experimental Study 5.6.7 Optimization of Tool Geometry References Appendix A - Basic Kinematics of Turning and Drilling A.1 Introduction A.2 Turning and Boring A.2.1 Basic Motions in Turning A.2.2 Cutting Speed in Turning and Boring A.2.3 Feed and Feed Rate A.2.4 Depth of Cut A.2.5 Material Removal Rate A.2.6 Resultant Motion A.3 Drilling and Reaming A.3.1 Basic Motions in Drilling A.3.2 Machining Regime A.4 Cutting Force and Power A.4.1 Force System in Metal Cutting A.4.2 Cutting Power A.4.3 Practical Assessment of the Cutting Force References Appendix B - ANSI and ISO Turning Indexable Inserts and Holders B.1 Indexable Inserts B.1.1 ANSI Code B.1.2 ISO Code B.2 Tool Holders for Indexable Inserts (Single Point Tools) B.2.1 Symbol for the Method of Holding Horizontally Mounted Insert – Reference Position (1) B.2.2 Symbol for Insert Shape – Reference Position (2) B.2.3 Symbol for Tool Style – Reference Position (3) B.2.4 Letter Symbol Identifying Insert Normal Clearance – Reference Position (4) B.2.5 Symbol for Tool Hand – Reference Position (5) B.2.6 Symbol for Tool Height (Shank Height of Tool Holders and Height of Cutting Edge) – Reference Position (6) B.2.7 Number Symbol Identifying Tool Holder Shank Width – Reference Position (7) B.2.8 Number Symbol Identifying Tool Length – Reference Position (8) B.2.9 Letter Symbol Identifying Indexable Insert Size – Reference Position (9) Appendix C - Basics of Vector Analysis C.1 Vectors and Scalars C.2 Definition and Representation C.2.1 Definitions C.2.2 Basic Vector Operations C.3 Application Conveniences C.4 Rotation: Linear and Angular Velocities C.4.1 Planar Linear and Angular Velocities C.4.2 Rotation: The Angular Velocity Vector References Appendix D - Hydraulic Losses: Basics and Gundrill Specifics D.1 Hydraulic Pressure Losses – General D.1.1 Major Losses: Friction Factor D.1.2 Minor Losses (Losses Due to Form Resistance) D.2 Concept of the Critical MWF Velocity and Flow Rate D.2.1 MWF Flow Rate Needed for Reliable Chip Transportation D.2.3 Example D.1 D.3 Inlet Coolant Pressure D.4 Analysis of Hydraulic Resistances D.4.1 Analysis of Hydraulic Resistances Over Which the Designer Has No or Little Control D.4.2 Variable Resistances Over Which the Designer Has Control D.5 Practical Implementation in the Drill Design References Appendix E - Requirements to and Examples of Cutting Tool Drawings E.1 Introduction E.2 Tool Drawings – the Existant Practice E.3 Tool Drawing Requrements E.4 Examples of Tool Drawing References Index