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Factors influencing machining and their control
Journal of Manufacturing Systems Volume ll/No. 1
book review
can be used to integrate information related to design, manufacturing, shop-floor control, etc., within the IMPS framework. The book is concise and is interesting reading. It includes numerous illustrations, examples, and analogies that make the book stimulating and thought-provoking. It is highly recommended to all manufacturing engineers and managers who wish to ensure the future of their factories.
its width is less than 0.008 inches. At 0.008 inches chamfer width, the tool wears in normal fashion without fracture. This finding is of importance to automatic machining. A survey of modern metal cutting inserts is presented by B. North (Session I). Covered are uncoated and coated carbides, the latter with mono-and-multiple layers, cermets, ceramics, and silicon and sialon. Mention is made of diamond and cubic boron nitride coatings, Although currently still in the laboratory state, such coatings may well play a role in metalcutting inserts in the future. In addition to material aspects, the author discusses geometry and edge preparation. Experiments in high-speed machining (HSM) have been conducted for many years, but only in the last decade has this process achieved the level of a viable technology. An informative survey of HSM today is presented by J.S. Agapiou (Session IV). The most frequent application of HSM is in milling aluminum alloys, especially with end mills. A dozen companies in the US and abroad manufacture high speed spindles for this purpose. Their speeds range from 9,000 to 90,000 rpm, and power from 1.2 to 40 kw. At these rpm values, cutting speeds of up to nearly 3000 m/min, are employed for machining aluminum alloys using carbide tools. Ferrous, titanium, and nickel alloys are also machined at high speeds in the range of 40 (titanium) to 1500 rn/min (cast iron), using carbide, cubic boron nitride, cermet, diamond, and sialon tools. Ceramic inserts are also being used in some cases. In addition to end milling, peripheral and face milling, drilling, turning, and boring operations are performed on these materials at high cutting speeds. The author also discusses spindle features, machine-workpiece dynamics, chip formation, cutting force and temperature, surface integrity, and various specific applications of the HSM techniques. The yearly cost of metal machining in the US has been estimated at 120 to 150 billion dollars. This cost could be significantly reduced through better utilization of research and development results. The Proceedings contain valuable information on such results and should be read by all engineers involved with the machining of metals.
Dharmaraj Veeramani Purdue University
Factors Influencing Machining and Their Control Proceedings of an International Conference and Workshop Cincinnati, OH September 1989 M.E. Finn, editor ©ASM International 1990 ix + 195 pp. $62.40 Since 1974, the ASM International (formerly the American Society of Metals) has been promoting the science and technology of machining materials by organizing international conferences every other year. The current proceedings contain 21 papers presented at the conference held in the fall of 1989. This was the ninth in the series of conferences on machining topics organized by the Committee. Material aspects of the tool, workpiece, and cutting fluid have a profound effect on the metal machining process. It is not surprising that most papers address one or more of these aspects. The titles of all papers and names of authors are listed at the end of this review. A considerable amount of up-to-date material is presented, and a few examples based on the reviewer's personal interest are given. Ceramic cutting tools have come a long way in the fifty or so years of their existence, but brittle fracture is still their Achilles heel. A careful study by Val, Zimmerman, and Katbi (Session I) has shown that in machining steel, the failure of a ceramic tool containing aluminum oxide and titanium carbide (a grade commonly used for machining steel) will be through fracture or wear, depending upon the geometry of the chamfer. The unpredictable, highly undesirable brittle fracture occurs with a 20 ° edge chamfer when
Keynote Presentation: Metalcutting Technology Forecasting "The Next Decade and Beyond," J. Heaton. Session 1: "Reactivity and Wetting Ability of Nonmetallic Compounds on Cemented Carbide Tools," P. Helisto, A. Helle, and J. Pietikainen.
70
Journal of Manufacturing Systems Volume 11/No. 1
book review
"The Effects of Edge Geometry on the Machining Performance and Reliability of Ceramic Cutting Tools," Y. Val, et al. "The Brazing Cracks of Cemented Carbide Cutting Tools and Their Control," Z. Yuanjie. "Control Contact Machining of Aluminum and Brass," P. Liu and J. Black. "Indexable Metalcutting Inserts," B. North.
"Machinability of Steel Forgings and their Economic Production," H. Tonshoff and W. Kaestner. "Softening High Hardenability Steels for Machining and Cold Forming," D. Doane. Session IV: "Influence of Microstructure on the Machining of Steel," M. Finn. "High-Speed Machining," J. Agapiou. "Tool and Machine Condition Monitoring," L. Stockline. "Identification and Control of Metal Removal," I. Yellowley.
Session H: Workshop Keynote Presentation: "The Length and Breadth of Machinability," G. Kane. "Converting Machinability Data to Applications," W. Zdeblick. "Drills, Their Design and Application," R. Maxey.
Session V: "An Initiative for the Next Generation Workstation/ Machine Controller Architecture," B. Wilson. "A New Approach to Optimization of Machining Operations," M. Galopin, et al. "Sensor-Based Detection of Grinding Process Health," G. Hughes, et al. "Force Models for Practical Multi-Edge Cutting Tools and Real Time Process Optimization," I. Yellowley, et al. "The Development of a Split-Tool Dynamometer for Orthogonal Machining," D. Buryta, et al.
Session III: "Influencing Factors of the Microstructures of Modem High Strength Steels on Their Machining Behaviors," T. Araki, S. Yamamoto, and H. Nakajima. "The Effect of the Addition of Boron on the Chip Breakability in Low Carbon Resulfurized Leaded Steels," T. Shiraga, S. Ishizaki, and T. Sempei. "Effect of Layer Formation on the Machinability of Steels," H. Pontinen and M. Paju. "Machining Characteristics of SiC Whisker Reinforced Aluminum," P. Chen and Y. Miyake. "Optimizing the Microstructure of Leaded Free Machining Steel for Improved Machinability," S. Subramanian, et al. "Machinability of Resulphurized Medium-Carbon Steels With and Without Microalloying Elements," R. Mauti and N. Chang.
Session VI: "Two-Element Modeling of Machining Process," I. Zun. "Some Aspects of Metal Removal Fluids," E. Natchman. "Seeded Gel Abrasive Characteristics and Grinding Performance," M. Pshar. Professor M. Barash, Senior Editor Purdue University
71
book review
can be used to integrate information related to design, manufacturing, shop-floor control, etc., within the IMPS framework. The book is concise and is interesting reading. It includes numerous illustrations, examples, and analogies that make the book stimulating and thought-provoking. It is highly recommended to all manufacturing engineers and managers who wish to ensure the future of their factories.
its width is less than 0.008 inches. At 0.008 inches chamfer width, the tool wears in normal fashion without fracture. This finding is of importance to automatic machining. A survey of modern metal cutting inserts is presented by B. North (Session I). Covered are uncoated and coated carbides, the latter with mono-and-multiple layers, cermets, ceramics, and silicon and sialon. Mention is made of diamond and cubic boron nitride coatings, Although currently still in the laboratory state, such coatings may well play a role in metalcutting inserts in the future. In addition to material aspects, the author discusses geometry and edge preparation. Experiments in high-speed machining (HSM) have been conducted for many years, but only in the last decade has this process achieved the level of a viable technology. An informative survey of HSM today is presented by J.S. Agapiou (Session IV). The most frequent application of HSM is in milling aluminum alloys, especially with end mills. A dozen companies in the US and abroad manufacture high speed spindles for this purpose. Their speeds range from 9,000 to 90,000 rpm, and power from 1.2 to 40 kw. At these rpm values, cutting speeds of up to nearly 3000 m/min, are employed for machining aluminum alloys using carbide tools. Ferrous, titanium, and nickel alloys are also machined at high speeds in the range of 40 (titanium) to 1500 rn/min (cast iron), using carbide, cubic boron nitride, cermet, diamond, and sialon tools. Ceramic inserts are also being used in some cases. In addition to end milling, peripheral and face milling, drilling, turning, and boring operations are performed on these materials at high cutting speeds. The author also discusses spindle features, machine-workpiece dynamics, chip formation, cutting force and temperature, surface integrity, and various specific applications of the HSM techniques. The yearly cost of metal machining in the US has been estimated at 120 to 150 billion dollars. This cost could be significantly reduced through better utilization of research and development results. The Proceedings contain valuable information on such results and should be read by all engineers involved with the machining of metals.
Dharmaraj Veeramani Purdue University
Factors Influencing Machining and Their Control Proceedings of an International Conference and Workshop Cincinnati, OH September 1989 M.E. Finn, editor ©ASM International 1990 ix + 195 pp. $62.40 Since 1974, the ASM International (formerly the American Society of Metals) has been promoting the science and technology of machining materials by organizing international conferences every other year. The current proceedings contain 21 papers presented at the conference held in the fall of 1989. This was the ninth in the series of conferences on machining topics organized by the Committee. Material aspects of the tool, workpiece, and cutting fluid have a profound effect on the metal machining process. It is not surprising that most papers address one or more of these aspects. The titles of all papers and names of authors are listed at the end of this review. A considerable amount of up-to-date material is presented, and a few examples based on the reviewer's personal interest are given. Ceramic cutting tools have come a long way in the fifty or so years of their existence, but brittle fracture is still their Achilles heel. A careful study by Val, Zimmerman, and Katbi (Session I) has shown that in machining steel, the failure of a ceramic tool containing aluminum oxide and titanium carbide (a grade commonly used for machining steel) will be through fracture or wear, depending upon the geometry of the chamfer. The unpredictable, highly undesirable brittle fracture occurs with a 20 ° edge chamfer when
Keynote Presentation: Metalcutting Technology Forecasting "The Next Decade and Beyond," J. Heaton. Session 1: "Reactivity and Wetting Ability of Nonmetallic Compounds on Cemented Carbide Tools," P. Helisto, A. Helle, and J. Pietikainen.
70
Journal of Manufacturing Systems Volume 11/No. 1
book review
"The Effects of Edge Geometry on the Machining Performance and Reliability of Ceramic Cutting Tools," Y. Val, et al. "The Brazing Cracks of Cemented Carbide Cutting Tools and Their Control," Z. Yuanjie. "Control Contact Machining of Aluminum and Brass," P. Liu and J. Black. "Indexable Metalcutting Inserts," B. North.
"Machinability of Steel Forgings and their Economic Production," H. Tonshoff and W. Kaestner. "Softening High Hardenability Steels for Machining and Cold Forming," D. Doane. Session IV: "Influence of Microstructure on the Machining of Steel," M. Finn. "High-Speed Machining," J. Agapiou. "Tool and Machine Condition Monitoring," L. Stockline. "Identification and Control of Metal Removal," I. Yellowley.
Session H: Workshop Keynote Presentation: "The Length and Breadth of Machinability," G. Kane. "Converting Machinability Data to Applications," W. Zdeblick. "Drills, Their Design and Application," R. Maxey.
Session V: "An Initiative for the Next Generation Workstation/ Machine Controller Architecture," B. Wilson. "A New Approach to Optimization of Machining Operations," M. Galopin, et al. "Sensor-Based Detection of Grinding Process Health," G. Hughes, et al. "Force Models for Practical Multi-Edge Cutting Tools and Real Time Process Optimization," I. Yellowley, et al. "The Development of a Split-Tool Dynamometer for Orthogonal Machining," D. Buryta, et al.
Session III: "Influencing Factors of the Microstructures of Modem High Strength Steels on Their Machining Behaviors," T. Araki, S. Yamamoto, and H. Nakajima. "The Effect of the Addition of Boron on the Chip Breakability in Low Carbon Resulfurized Leaded Steels," T. Shiraga, S. Ishizaki, and T. Sempei. "Effect of Layer Formation on the Machinability of Steels," H. Pontinen and M. Paju. "Machining Characteristics of SiC Whisker Reinforced Aluminum," P. Chen and Y. Miyake. "Optimizing the Microstructure of Leaded Free Machining Steel for Improved Machinability," S. Subramanian, et al. "Machinability of Resulphurized Medium-Carbon Steels With and Without Microalloying Elements," R. Mauti and N. Chang.
Session VI: "Two-Element Modeling of Machining Process," I. Zun. "Some Aspects of Metal Removal Fluids," E. Natchman. "Seeded Gel Abrasive Characteristics and Grinding Performance," M. Pshar. Professor M. Barash, Senior Editor Purdue University
71