Geometry_of_Single_point_Turning_Tools_and_Drills

機器鼠

1 H* H! o9 i+ u+ bGeometry_of_Single_point_Turning_Tools_and_Drills__Fundamentals_and_Practical_Applications.pdf
' F: a& G0 p$ b4 D$ J, D有要的嗎,？刀具,，細節(jié)，很到位,。英文版,。
; a" C% |/ N5 b3 Q% s1 @9 ?6 Q國內(nèi)無人這么細研究的吧？

狙擊手

說什么的,？

機器鼠

Although almost any book and/or text on metal cutting, cutting tool design, and
! t6 v3 ~0 y9 ?# C) b5 r+ ]( lmanufacturing process discusses to a certain extent the tool geometry, the body of
3 n: b7 _4 e  i# xknowledge on the subject is scattered and  confusing. Moreover, there is no clear
5 p: x, K4 m/ a8 w4 l$ mobjective(s) set in the selection of the tool geometry parameters so that an answer
to a simple question about optimal tool geometry cannot be found in the literature
on the subject. This is because a criterion (criteria) of optimization is not clear, on
: z# k* H& T0 w  l$ W% @$ e# Xone hand, and because the role of cutting tool geometry in machining process
6 v# e4 s% ~( V# ioptimization has never been studied systematically, on the other. As a result, many
7 P# o) b2 d) s" T- _% E9 Dpractical tool/process designers are forced to use extremely vague ranges of tool
geometry parameters provided by handbooks. Being at least 20+ years outdated,
these data do not account for any particularities of a machining operation including
a particular grade of tool material, the condition of the machine used, the cutting
/ x6 p# ^$ W8 zfluid, properties and metallurgical condition of the work material, requirements to
  j' d, [9 ]) _2 \the integrity of the machined surface, etc.
9 {# n$ e1 m+ l% L9 WUnfortunately, while today's professionals, practitioners, and students are
interested in cutting tool geometry, they are doomed to struggle with the confusing
9 Z1 k9 o2 ?- Uterminology. When one does not know what the words (terms) mean, it is easy to
! l( ~' |$ ?2 rslip into thinking that the matter is difficult, when actually the ideas are simple,
easy to grasp, and fun to consider. It is the terms that get in the way, that stand as a
$ ~5 C9 y% [. f6 wwall between many practitioners and science. This books attempts to turn those
0 z  L, i1 |# d: U2 Jwalls into windows, so that readers can peer in and join in the fun of proper tool
design.
6 U, ?- |1 x' B' m) P# {9 WSo, why am I writing this book? There are a few reasons, but first and foremost,
+ J. g, _  M7 O6 U$ K! l" d+ H  zbecause I am a true believer in what we call technical literacy. I believe that
* X8 i7 w9 y6 G- j2 L1 Reveryone involved in the metal cutting business should understand the essence and
4 H/ f2 R% I4 S$ O* \& ?0 yimportance of cutting tool geometry. In my opinion, this understanding is key to
improving efficiency of practically all machining operations. For the first time, this
* i5 P$ Q% a0 m% h8 a) \' p2 Qbook presents and explains the direct correlations between tool geometry and tool
performance. The second reason is that I felt that there is no comprehensive book
on the subject so professionals, practitioners, and students do not have a text from
which to learn more on the subject and thus appreciate the real value of tool
) ?7 H6 n" j6 ~! |geometry. Finally, I wanted to share the key elements of tool geometry that I felt
were not broadly understood and thus used in the tool design practice and in
optimization of machining operations in industry. Moreover, being directly
! _- c5 f+ i& d+ G3 c/ x0 qinvolved in the launch of many modern manufacturing facilities equipped with
1 n/ e$ Q! w8 fstate-of-the-art high-precision machines, I found that the cutting tool industry is not
ready to meet the challenge of modern metal cutting applications. One of the key
; L; j; y! X( {' ]" lissues is the definite lack of understanding of the basics of tool geometry of
standard and application-specific tools.
8 k+ B# D/ i- i0 P$ BThe lack of information on cutting tool geometry and its influence on the
outcome of machining operations can be explained as follows. Many great findings
0 ?" n2 f2 B4 Mon tool geometry were published a long time ago when neither CNC grinding
machines capable of reproducing any kind of tool geometry were available nor
$ \) O6 w: P! V6 P6 W  b% Owere computers to calculate parameters of such geometry (using numerical
methods) common. Manual grinding using standard 2- and 3-axis simple grinding
features was common so the major requirement for tool geometry was the simpler
the better. Moreover, old, insufficiently rigid machines, aged tool holders and part
  w  u* F2 T- ^: O1 A) Mfixtures, and poor metal working fluid (MWF) selection and maintenance levered
6 ^) R3 ]! K5 s6 N! uany advancement in tool geometry as its influence could not be distinguished under
these conditions. Besides, a great scatter in the properties of tool materials in the
3 f) c  D# ?$ _6 Bpast did not allow distinguishing of the true influence of tool geometry. As a result,
' u1 G8 d' |1 A. T% gstudies on tool geometry were reduced to  theoretical considerations of features of
twist drills and some gear manufacturing  tools such as hobs, shaving cutters,
/ g7 j; n$ ]# A2 h2 v5 j. hshapers, etc.  
Gradually, once mighty chapters on tool geometry in metal cutting and tool
design books were reduced to sections of few pages where no correlation between
tool geometry and tool performance is normally considered. What is left is a
general perception that the so-called “positive geometry” is somehow better than
; c: T( n) {2 A0 v3 w“negative geometry.” As such, there is no quantitative translation of the word
# `# ~0 [/ {* I8 b0 l' C“better” into the language  of technical data although a great number of articles
written in many professional magazines discuss the qualitative advantages of
4 K+ e) K- m- F2 |" \“positive geometry.” For example, one popular manufacturing magazine article
4 D+ G8 l; F7 F9 _, o9 Uread “Negative rake tools have a much  stronger leading edge and tend to push
against the workpiece in the direction of the cutter feed. This geometry is less free
cutting than positive rakes and so consumes more horsepower to cut.” Reading
these articles one may wonder why cutting tool manufacturers did not switch their
tool designs completely to this mysterious “positive geometry” or why some of
- x3 T; X' P; |. Q; Fthem still investigate and promote negative geometry.
During recent decades, the metalworking industry underwent several important
changes that should bring cutting tool geometry into the forefront of tool design
% M! K/ r' {! u# r4 R/ D; Uand implementation:

機器鼠

1   What Does It Mean “Metal Cutting”? ...........................................................1
9 O5 t3 `+ M: V2 v- ]1.1   Introduction ...............................................................................................1
! o. [4 |7 [9 I# o( i1.2   Known Results and Comparison with Other Forming Processes ..............2
  1.2.1   Single-shear Plane Model of Metal Cutting ...................................2
: Y( a+ V! C8 v9 q5 c' c  1.2.2   Metal Cutting vs. Other Closely Related Manufacturing  
Operations .................................................................................................5
1.3   What Went Wrong in the Representation of Metal Cutting?...................22
  1.3.1   Force Diagram..............................................................................23
  1.3.2   Resistance of the Work Material in Cutting.................................25
  1.3.3   Comparison of the Known Solutions for the Single-shear  
  Plane Model with Experimental Results .................................................27
1.4   What is Metal Cutting?............................................................................28
9 e6 U- S: @4 ~: E! ~, {  1.4.1   Importance to Know the Right Answer........................................28
1.4.2  Definition .....................................................................................28
  1.4.3   Relevance to the Cutting Tool Geometry.....................................29
1.5   Fundamental Laws of Metal Cutting.......................................................32
  1.5.1   Optimal Cutting Temperature – Makarow’s Law........................32
8 Q, }) w9 ^8 B4 {. G+ j1 h: ~ 1.5.2  Deformation Law.........................................................................35
# a7 Y# X7 g( ?2 i( C- K/ ZReferences........................................................................................................50
& E/ m. }  z/ [# E7 Q 2   Basic Definitions and Cutting Tool Geometry,  
Single Point Cutting Tools ............................................................................55
2.1   Basic Terms and Definitions ...................................................................55
) k( |$ A  o6 g/ ] 2.1.1  Workpiece Surfaces.......................................................................57
2.1.2  Tool Surfaces and Elements ..........................................................57
2.1.3  Tool and Workpiece Motions.......................................................57
8 ]" c6 G5 _" h- I% ] 2.1.4  Types of Cutting ............................................................................58
2.2   Cutting Tool Geometry Standards...........................................................60
2.3   Systems of Consideration of Tool Geometry ..........................................61
2.4.  Tool-in-hand System (T-hand-S) .......................................................64
/ b4 }4 Z7 R  S, P! y$ p  2.4.1   Tool-in-hand Coordinate System.................................................64
( o, i) J2 M; X2 x7 m$ [ 2.4.2  References Planes ........................................................................66
6 D: P4 ~' j( [3 A 2.4.3  Tool Angles..................................................................................68
  2.4.4   Geometry of Cutting Tools with Indexable Inserts ......................74
9 N1 l4 {! o, x5 r/ J2.5   Tool-in-machine System (T-mach-S)......................................................84
2.5.1  Angles ..........................................................................................84
6 N) [$ s6 k/ |9 o+ M! H  2.5.2   Example 2.3 .................................................................................88
) |# \/ D. l4 M7 I6 E2.6   Tool-in-use System (T-use-S) .................................................................90
1 `! V5 s; ]  N" B0 n 2.6.1  Reference Planes ..........................................................................91
1 \# h4 l' M0 l, Y1 A, O3 @ 2.6.2  The Concept .................................................................................92
  2.6.3   Modification of the T-hand-S Cool Geometry .............................92
2 e0 ^# X8 v3 }1 [  2.6.4   Kinematic Angles.........................................................................98
  2.6.5   Example 2.4 ...............................................................................100
2.7   Avalanched Representation of the Cutting Tool Geometry  
in T-hand-S............................................................................................102
1 }9 P/ a) `7 B& F6 z- `4 h 2.7.1  Basic Tool Geometry .................................................................102
& V& z% s' ?3 B; B6 S$ @. c2.7.2   Determination of Cutting Tool Angles Relation
* ^6 D3 b: n. e8 w6 U$ Q  for a Wiper Cutting Insert ..........................................................108
  2.7.3   Determination of Cutting Tool Angles  
9 X2 {' B8 M* c6 k   for a Single-point Tool ...............................................................110
5 ?/ t: T( i1 v- i- V  2.7.4   Flank Angles of a Dovetail Forming Tool .................................117
  2.7.5   Summation of Several Motions..................................................119
3 {3 |; E5 \) P& u  k6 b$ R: Y7 NReferences......................................................................................................125
  Z, u: k5 k. t- [' T0 b, Y1 N3  Fundamentals of the Selection of Cutting Tool Geometry Parameters...127
" s/ `4 e/ R2 F; k5 F% W& W3.1   Introduction ...........................................................................................127
/ @* l* o  h5 v& @. ^' F9 [) U3.2   General Considerations in the Selection of Parameters  
  of Cutting Tool Geometry .....................................................................129
$ W  t- j! e4 [8 c4 _% p/ B8 H& s 3.2.1 Known Results .............................................................................129
  3.2.2 Ideal Tool Geometry and Constrains............................................130
  3.2.3 Practical Gage for Experimental Evaluation of Tool Geometry...132
3.3   Tool Cutting Edge Angles .....................................................................132
& {0 `% d0 O$ l: p1 {; K 3.3.1  General Consideration................................................................132
  3.3.2   Uncut ChipT in Non-free Cutting ..............................................134
7 T7 M$ F9 s* R* p0 Q) h  3.3.3   Influence on the Surface Finish..................................................142
3.3.4  Tools with κr > 90°.....................................................................144
  3.3.5   Tool Minor Cutting Edge Angle ................................................147
3.4.  Edge Preparation ...................................................................................161
3.4.1  General .......................................................................................161
  3.4.2   Shape and Extent........................................................................163
3.4.3  Limitations .................................................................................163
  3.4.4   What Edge Preparation Actually Does.......................................169
1 e  N- X1 e- p3.5   Rake Angle............................................................................................171
8 C+ w- j2 ^: \% e6 Z 3.5.1  Introduction................................................................................171
# M! O& M% c( L* Z" h, L  3.5.2   Influence on Plastic Deformation and Generazliations ..............175
, ^, K4 R* R5 H) T  3.5.3   Effective Rake Angle .................................................................183
  3.5.4   Conditions for Using High Rake Angles....................................189
3.6   Flank Angle ...........................................................................................191
3.7   Inclination Angle...................................................................................193
6 \( p$ o# e; V" m      3.7.1   Turning with Rotary Tools.........................................................195
; \7 @+ P- ]- W" T1 g- o 3.7.2  Helical Treading Taps and Broaches..........................................197
3.7.3  Milling Tools..............................................................................198
References......................................................................................................201
4   Straight Flute and Twist Drills ...................................................................205
4.1   Introduction ...........................................................................................205
/ C( X2 p1 Z+ l: N3 ^1 Z$ e4 a4.2   Classification.........................................................................................206
4.3   Basic Terms...........................................................................................208
4.4   System Approach ..................................................................................211
4.4.1  System Objective .......................................................................212
4.4.2  Understanding the Drilling System............................................212
+ Q6 M0 W1 \- ~  Y  4.4.3.  Understanding the Tool..............................................................212
! g$ e: N$ Q% i+ A' ~& |4 |7 D) n( w4.5.  Force System Constrains on the Drill Penetration Rate ........................213
, z" Q3 Q% K/ ]# c; j* v$ x+ z  4.5.1   Force-balance Problem in Conventional Drills ..........................213
/ s# M# Z8 D( G. L/ R0 J4 O; |  4.5.2   Constrains on the Drill Penetration Rate....................................218
; ?$ H3 K1 W; A; p5 T3 B 4.5.3  Drilling Torque ..........................................................................219
4.5.4  Axial Force.................................................................................220
  a9 c5 L- z4 ]/ S  4.5.5   Axial Force (Thrust)-torque Coupling .......................................221
& L3 A5 X& s8 Q. i4.6   Drill Point ..............................................................................................223
. t7 Q1 T9 U0 v: B) m 4.6.1  Basic Classifications ..................................................................223
  4.6.2   Tool Geometry Measures to Increase the Allowable  
9 r% \+ [/ x$ P4 r! R Penetration Rate ....................................................................................224
- E; \: v6 [6 @9 L+ B4.7   Common Design and Manufacturing Flaws..........................................259
  4.7.1   Web Eccentricity/ Lip Index Error.............................................260
, t  Q/ ~+ g1 b) p# [+ {3 L  4.7.2   Poor Surface Finish and Improper Tool Material/Hardness.......261
4.7.3  Coolant Hole Location and Size.................................................263
' m1 `/ A9 t2 q" f- x8 `4.8   Tool Geometry ......................................................................................267
$ G$ V9 h* F% `; Z0 u  4.8.1   Straight-flute and Twist Drills Particularities............................269
  4.8.2   Geometry of the Typical Drill Point ..........................................270
1 _9 `7 U  c5 w5 |  4.8.3   Rake Angle.................................................................................272
  4.8.4  Inclination Angle .........................................................................280
7 e# `2 t4 T2 ~: x/ d' ~( h' j 4.8.5  Flank Angle................................................................................281
: i" N, Q) n; X. f& v3 u  4.8.6   Geometry of a Cutting Edge Located at an Angle  
; ~8 r/ I& K% D( j3 J/ w   to the y0-plane ............................................................................292
. Y) O0 i" N/ H- C+ q  m3 F7 Q 4.8.7  Chisel Edge ................................................................................295
7 ?0 N2 m9 Z6 e9 ?3 n+ ^  4.8.8   Drill Flank is Formed by Two Planes: Generalization...............306
  4.8.9   Drill Flank Angle Formed by Three Planes ...............................310
; L5 g5 v* A: `6 @3 u6 i% u4 `+ R 4.8.10  Flank Formed by Quadratic Surfaces.........................................313
4.9   Load Over the Drill Cutting Edge .........................................................324
' M1 W6 ]! ]' s# W   4.9.1   Uncut Chip Thickness in Drilling ..............................................325
/ e: N+ _# `& C  Y  4.9.2   Load Distribution Over the Cutting Edge ..................................327
4.10  Drills with Curved and Segmented Cutting Edges ................................328
/ l2 S4 |3 D4 i0 q. `/ N1 x, o  4.10.1 Load of the Cutting Part of a Drill with Curved Cutting Edges .329
( s- g6 @, F3 {/ f* M  4.10.2 Rake Angle.................................................................................332
References......................................................................................................337
5   Deep-hole Tools............................................................................................341
5 y1 H& w7 P, P/ T! x5.1   Introduction ...........................................................................................341
- |7 U6 d7 ^+ x9 s; _+ k) P2 C5.2   Generic Classification of Deep-hole Machining Operations.................343
5.3   What Does ‘Self-piloting Tool’ Mean? .................................................345
% t+ R* O- D: X( D  5.3.1   Force Balance in Self-piloting Tools..........................................345
. \6 M. ?+ z+ ]! @/ e9 {5.4   Three Basic Kinematic Schemes of Drilling .........................................350
  5.4.1   Gundrill Rotates and the Workpiece is Stationary .....................351
5.4.2  Workpiece Rotates and the Gundrill is Stationary .....................352
5 F2 K3 V+ G$ q) L" t9 @0 f- j/ i 5.4.3  Counterrotation ..........................................................................352
5.5   System Approach ..................................................................................353
% n$ J/ p* U; r# N  5.5.1   Handling Tool Failure ................................................................353
: O' e3 G8 X' M' H 5.5.2  System Considerations ...............................................................354
5.6   Gundrills................................................................................................362
5.6.1  Basic Geometry..........................................................................362
  T- L4 n, k/ X3 S7 ] 5.6.2  Rake Surface ..............................................................................365
  5.6.3   Geometry of Major Flanks .........................................................370
3 I1 D1 x+ ~' [0 e% s" }4 k 5.6.4  System Considerations in Gundrill Design ................................390
0 S! e$ J6 V% u8 O, s5.6.5   Examplification of Significance of the High MWF Pressure
  in the Bottom Clearance Space ..................................................423
  5.6.6   Example of Experimental Study ................................................425
  5.6.7   Optimization of Tool Geometry.................................................439
References......................................................................................................440
Appendix A  
Basic Kinematics of Turning and Drilling.......................................................443
1 v" B$ ?9 d+ dA.1   Introduction ...........................................................................................443
$ w6 {; w% d5 j+ n  M& W2 oA.2  Turning and Boring ...............................................................................444
  A.2.1  Basic Motions in Turning...........................................................444
  A.2.2  Cutting Speed in Turning and Boring ........................................448
( j' J2 w. P7 U' m9 \  A.2.3  Feed and Feed Rate ....................................................................448
  A.2.4  Depth of Cut...............................................................................449
# ^- E. y* S  J  d A.2.5  Material Removal Rate ..............................................................449
A.2.6  Resultant Motion........................................................................450
# o, J# P; R5 kA.3  Drilling and Reaming ............................................................................450
A.3.1  Basic Motions in Drilling...........................................................450
A.3.2  Machining Regime.....................................................................451
# i5 ?2 [$ ^" ^& |! I& M- G% K4 [: d: ~A.4  Cutting Force and Power .......................................................................453
5 X$ O( K) |# a( i' C  A.4.1  Force System in Metal Cutting...................................................453
9 Q5 B- r& @7 X( T5 Q, p  A.4.2  Cutting Power ............................................................................454
4 v7 i+ C$ N" Z8 t* m3 F7 o A.4.3  Practical Assessment of the Cutting Force.................................455
& Q2 t7 a  n) R$ YReferences......................................................................................................461
* q0 a( t1 g0 y) t# F5 e+ T9 y+ B$ VAppendix B  
ANSI and ISO Turning Indexable Inserts and Holders.................................463
3 H3 A' W8 x7 r1 C5 |B.1   Indexable Inserts ...................................................................................463
+ q" i7 b, q  j! X) O5 Y  B.1.1  ANSI Code .................................................................................464
B.1.2  ISO Code....................................................................................471
3 r9 }' x( s4 @# O  B.2 Tool Holders for Indexable Inserts (Single Point Tools) ......................491
  B.2.1   Symbol for the Method of Holding Horizontally Mounted  
Insert – Reference Position (1) ..............................................................492
8 a2 e% E- y! T  B.2.2   Symbol for Insert Shape – Reference Position (2) .....................493
- R8 I8 L- M) H% i# S  p+ m  B.2.3   Symbol for Tool Style – Reference Position (3) ........................493
' Y+ @; r' q* Z7 ?- n" I1 B  B.2.4   Letter Symbol Identifying Insert Normal Clearance –  
   Reference Position (4)................................................................494
  B.2.5   Symbol for Tool Hand – Reference position (5) ........................494
  B.2.6  Symbol for Tool Height (Shank Height of Tool Holders  
; |( O/ x) L$ [7 a3 X    and Height of Cutting Edge) - Reference Position (6) ...............494
2 u4 O6 G6 ?: ~$ k  B.2.7  Number Symbol Identifying Tool Holder Shank Width –  
   Reference Position (7)................................................................495
# N8 X$ s7 S6 v' E  B.2.8  Number Symbol Identifying Tool Length –  
7 D" F7 P$ @8 I4 l4 F   Reference Position (8)................................................................495
' I- D+ O4 y" N4 y  B.2.9   Letter Symbol Identifying Indexable Insert Size –  
   Reference Position (9)................................................................497
Appendix C  
Basics of Vector Analysis ..................................................................................499
) I. g5 v9 E# l, N" TC.1   Vectors and Scalars ...............................................................................499
C.2   Definition and Representation...............................................................500
+ X3 Y! H2 C& `' {9 Q8 K C.2.1  Definitions..................................................................................500
C.2.2  Basic Vector Operations ............................................................503
! m7 s8 M; A) }& [3 IC.3   Application Conveniences.....................................................................509
" w- i, N& N4 y! AC.4  Rotation: Linear and Angular Velocities...............................................511
  C.4.1   Planar Linear and Angular Velocities ........................................511
  C.4.2   Rotation: The Angular Velocity Vector .....................................515
$ [% B, V3 K- }9 D& v8 V1 z! W1 vReferences ...........................................................................................................518
4 ^1 w, B/ U# e6 G% OAppendix D  
+ E- t) p' R7 I. ^4 Y! |3 t; RHydraulic Losses: Basics and Gundrill Specifics............................................519
( ~+ J2 Z# w; G, K+ M2 g1 tD.1  Hydraulic Pressure Losses – General ....................................................519
D.1.1  Major Losses: Friction Factor ....................................................520
/ w8 [( Q& D3 x3 e1 V  D.1.2  Minor Losses (Losses Due to Form Resistance) ........................521
7 u- y, A4 J( F' m; \ D.2  Concept of the Critical MWF Velocity and Flow Rate .........................521
* t1 v: M2 p, R! R  D.2.1  MWF Flow Rate Needed for Reliable Chip Transportation.......522
% m! C5 }1 B/ @4 H1 j% l5 _  D.2.3  Example D.1...............................................................................527
D.3   Inlet MWF pressure...............................................................................528
/ F2 f3 c- g9 P9 AD.4  Analysis of Hydraulic Resistances ........................................................532
( U* L0 x* i3 X! t4 ~& E- [( L! ]/ ?1 ~  D.4.1  Analysis of Hydraulic Resistances Over Which the Designer  
# Q: ]4 k. r6 M    Has No or Little Control ............................................................532
- D+ J% p+ C+ E2 D# J7 [  D.4.2  Variable Resistances Over Which the Designer Has Control ....535
' `% i, b0 v1 R/ l& h$ JD.5   Practical Implementation in the Drill Design ........................................539
References ..........................................................................................................543
; X4 S* Y/ c6 M% w- e1 {Appendix E
Requirements and Examples of Cutting Tool Drawings................................545
4 w4 n' K$ |. S. CE.1   Introduction ...........................................................................................545
E.2   Tool Drawings – the Existent Practice ..................................................546
! S0 O7 u" ^6 i3 J% k" DE.3   Tool Drawing Requrements ..................................................................548
E.4   Examples of Tool Drawing ...................................................................553
, c9 L- H* g+ O( mReferences ..........................................................................................................559
Index…………………………………………………………………………….561

, i- A' ~5 w* i( F  d( k

李東ld

都是些神馬,？

showmark

埋頭挖礦中。。,。,。。,。,。。,。

lpg1988

好東西啊。,。,。只是，刀具不是我的工作,。,。。頂起,，不沉,。。,。

機器鼠

專業(yè)人士自有看法,。

招魂者

好東西啊，英文的,，看著太費勁了

招魂者

從網(wǎng)上查找這本書是Springer Series in Advanced Manufacturing叢書中的一本
請問這套叢書共包含哪幾本書