Analysis of Machining and Machine Tools

Analysis of Machining and Machine Tools
Steven Y. Liang, Albert J. Shih
Contents
1 Introduction . 1
1.1 Basic Defnitions . 1
1.2 Historical Development of Machining Technology . 2
1.3 Overview of Machining Processes and Systems . 3
1.4 General Requirements in the Construction of Machine Tools . 6
2 Single-Point Cutting Processes . 9
2.1 Motions in Machining . 9
2.2 Machine Tools Using Single-Point Cutters . 10
3 Multiple Point Cutting Processes 25
3.1 Milling Machine and Milling Process . 25
3.2 Drilling Process 38
4 Grinding Processes . 45
4.1 Grinding Machine and Process Overview 45
4.2 Grinding Wheel Code . 46
4.3 Surface Grinding . 47
4.4 Cylindrical Grinding 54
4.5 Special Grinding Processes . 60
5 Machine Tool Components . 63
5.1 Frames . 64
5.2 Slides and Rails 71
5.3 Motors . 73
5.4 Spindles 78
5.5 Tool Materials . 82
5.6 Controls 85
6 Machine Tool Accuracy and Metrology 95
6.1 Acceptable Accuracy of Machine Tools . 95
6.2 Machine Tool Accuracy 96
6.3 Random Error and Tolerance Template 102
6.4 Machine Tool Metrology . 103x Contents
7 Mechanics of Machining . 113
7.1 Orthogonal Cutting Model 113
7.2 Forces in Orthogonal Cutting . 114
7.3 Stresses . 117
7.4 Shear Angle . 117
7.5 Velocities . 125
7.6 Shear Strain and Shear Strain Rate . 127
7.7 Cutting Energy . 128
8 Shear Stress in Cutting 133
8.1 Strain Rate and Temperature 133
8.2 Effect of Normal Stress 136
8.3 Inhomogeneous Strain . 137
9 Cutting Temperature and Thermal Analysis 141
9.1 The Measurement of Cutting Temperatures . 141
9.2 Heat Generation in Machining . 144
9.3 Temperature Distribution in Machining 146
10 Machine Tool Chatter . 155
10.1 Machining Dynamics . 155
10.2 Arnold-Type Chatter . 157
10.3 Regenerative Chatter . 162
11 Electrical Discharge Machining . 167
11.1 EDM—An Overview . 168
11.2 Sinking and Wire EDM . 169
11.3 Discharge Material Removal Mechanism
and Dielectric Medium . 169
11.4 EDM Pulses and Process Monitoring 171
11.5 EDM Generators 172
11.6 EDM Surface Integrity 177
11.7 Conclusions 178
12 Electrochemical Machining, Chemical Machining,
and Chemical Mechanical Polishing Processes 181
12.1 Electrochemical Machining 181
12.2 Chemical Machining . 187
12.3 Chemical Mechanical Polishing 189
13 Laser and Electron Beam Machining 193
13.1 Laser Beam Machining . 193
13.2 Electron Beam Machining . 202Contents xi
14 Biomedical Machining 207
14.1 Oblique Cutting of Soft Tissue . 208
14.2 Needle Cutting Edges 211
14.3 Force for Blade and Needle Insertion 216
14.4 Needle Tip Grinding . 218
14.5 Optimal Needle with Lancet Point . 220
14.6 Biomedical Grinding: Dental, Skull Base
Neurosurgery, and Atherectomy 222
14.7 Electrosurgical Processes and Thermal Dose Model . 225
14.8 Concluding Remarks . 226
References
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