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E-raamat: Basics of Cutting and Abrasive Processes

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Basics of Cutting and Abrasive ProcessesSuurem pilt
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Cutting and abrasive technologies are the backbone of precision production in machine, automotive and aircraft building as well as of production of consumer goods. This book presents the knowledge of modern manufacturing in these technologies.

Manufacturing is the basic industrial activity generating real value. Cutting and abrasive technologies are the backbone of precision production in machine, automotive and aircraft building as well as of production of consumer goods. We present the knowledge of modern manufacturing in these technologies on the basis of scientific research. The theory of cutting and abrasive processes and the knowledge about their application in industrial practice are a prerequisite for the studies of manufacturing science and an important part of the curriculum of the master study in German mechanical engineering. The basis of this book is our lecture “Basics of cutting and abrasive processes” (4 semester hours/3 credit hours) at the Leibniz University Hannover, which we offer to the diploma and master students specializing in manufacturing science.
1 Introduction to the Technology of Cutting and Abrasive Processes 1(20)
1.1 Economic Relevance
1(2)
1.2 Taxonomy
3(1)
1.3 Motions, Angles at the Cutting Edge and Engagement Parameters
4(4)
1.4 Cutting and Abrasive Processes as Black Box Systems
8(1)
1.5 Process Types and Engagement Parameters in Drilling
9(6)
1.6 Process Types and Engagement Parameters in Milling
15(3)
1.7 Questions
18(1)
References
19(2)
2 Chip Formation 21(16)
2.1 Mechanisms of Chip Formation
21(4)
2.2 Chip Root Analysis
25(4)
2.3 Shear Plane Model
29(6)
2.4 Questions
35(1)
References
36(1)
3 Chip Control 37(12)
3.1 Chip Volume Ratio and Chip Form Classification
37(1)
3.2 Chip Guidance
38(4)
3.3 Influence of the Workpiece Material
42(3)
3.4 Influence of the Cutting Conditions
45(1)
3.5 Questions
46(2)
References
48(1)
4 Forces and Powers in Cutting and Abrasive Processes 49(34)
4.1 Empirical Models
50(9)
4.2 Modeling of the Feed Force and the Passive Force
59(1)
4.3 Surface Forces at the Cutting Edge
60(3)
4.4 Analytical Approaches in Plastomechanics
63(3)
4.4.1 Theory by Ernst and Merchant
63(1)
4.4.2 Hucks's Theory
64(2)
4.5 Flow Curves and Constitutive Equations
66(2)
4.6 Numerical Theory
68(2)
4.7 Powers, Torques and Forces in Drilling
70(6)
4.8 Power and Forces in Milling Processes
76(4)
4.9 Questions
80(1)
References
81(2)
5 Energy Conversion and Temperature 83(22)
5.1 Conversion Effects
83(3)
5.2 Heat Flow
86(3)
5.3 Temperatures of Cutting Wedge and Workpiece
89(12)
5.3.1 Temperature Measurement
89(7)
5.3.2 Temperature Fields
96(5)
5.4 Optimization of the Cutting Wedge
101(1)
5.5 Questions
102(1)
References
103(2)
6 Modeling and Simulation 105(24)
6.1 Kinematic Simulation
106(13)
6.1.1 Representation of the Workpiece
108(6)
6.1.2 Tool Model
114(1)
6.1.3 Determination of Process Values
115(4)
6.2 Numerical Simulation by FEM
119(4)
6.3 Molecular Dynamic Modeling
123(3)
6.4 Questions
126(1)
References
126(3)
7 Wear 129(30)
7.1 Wear Forms
129(3)
7.2 Loading
132(6)
7.3 Wear Mechanisms
138(2)
7.4 Tool Life
140(6)
7.5 Tool Life Scatter and Process Reliability
146(2)
7.6 Influence of Work Material on Wear
148(5)
7.6.1 Work Material Composition
149(1)
7.6.2 Melting Procedure
150(2)
7.6.3 Heat Treatment
152(1)
7.7 Rounding of the Cutting Edge
153(3)
7.8 Questions
156(1)
References
157(2)
8 Cutting Materials 159(30)
8.1 Requirements on Cutting Materials
159(4)
8.2 Tool Steels
163(1)
8.3 High Speed Steels
163(2)
8.4 Stellites
165(1)
8.5 Cemented Carbides
166(8)
8.6 Cermets
174(2)
8.7 Ceramics
176(5)
8.8 Diamond
181(2)
8.8.1 Mono-Crystalline Diamond
181(1)
8.8.2 Polycrystalline Diamond
181(2)
8.9 Boron Nitride
183(3)
8.10 Questions
186(1)
References
187(2)
9 High Speed Cutting 189(12)
9.1 Definition
189(3)
9.2 Chip Formation
192(1)
9.3 Application
193(3)
9.4 High Power Cutting
196(1)
9.5 High Power Drilling
196(2)
9.6 Questions
198(1)
References
199(2)
10 Hard Machining, Process Design 201(20)
10.1 Hard Turning
201(6)
10.2 Hard Drilling
207(2)
10.3 Hard Milling
209(2)
10.4 Materials
211(1)
10.5 Chip Formation, Forces and Temperature
212(5)
10.6 Cutting Materials and Tool Wear
217(1)
10.7 Questions
218(1)
References
219(2)
11 Hard Machining, Component Quality 221(16)
11.1 Macro Geometrical Deviations
221(3)
11.2 Micro Geometrical Properties
224(2)
11.3 Physical Influence
226(1)
11.4 Rolling Fatigue Strength
227(1)
11.5 Fatigue Strength
228(2)
11.6 Sealability
230(1)
11.7 Post-treatment Processes
231(3)
11.7.1 Hard Roller Burnishing
231(2)
11.7.2 Water Peening
233(1)
11.8 Questions
234(1)
References
235(2)
12 Broaching 237(10)
12.1 Broaching Process
237(5)
12.2 Machine Development
242(4)
12.3 Questions
246(1)
References
246(1)
13 Grinding 247(56)
13.1 Cutting with Geometrically Undefined Cutting Edges
247(3)
13.2 Grinding Materials
250(7)
13.2.1 Corundum
251(2)
13.2.2 Silicon Carbide
253(1)
13.2.3 Cubic Crystalline Boron Nitride and Diamond
254(1)
13.2.4 Grain Sizes of Grinding Materials
255(2)
13.3 Bonding
257(1)
13.4 Grinding Wheels
258(3)
13.5 Burst Safety of Grinding Wheels
261(4)
13.6 Grinding Processes
265(21)
13.6.1 Input Variables
266(10)
13.6.2 Process Variables
276(3)
13.6.3 Output Variables
279(7)
13.7 Conditioning of Grinding Tools
286(9)
13.7.1 Basics
286(4)
13.7.2 Conditioning of Conventional Grinding Wheels
290(2)
13.7.3 Conditioning of Super Hard Grinding Wheels
292(3)
13.8 Grinding Costs
295(1)
13.9 Questions
296(1)
References
297(6)
14 Gear Grinding 303(22)
14.1 Introduction
303(5)
14.2 Discontinuous Profile Grinding
308(4)
14.3 Continuous Generating Grinding with Grinding Worms
312(4)
14.4 Continuous Crossed Helical Grinding
316(4)
14.5 Questions
320(1)
References
321(4)
15 Process Layout and Integration into the Process Chain 325(24)
15.1 Basics of Process Chain Layout
325(3)
15.1.1 Technological Interfaces
326(1)
15.1.2 Process Chain Layout
327(1)
15.2 Process Model Generation
328(3)
15.3 Process Layout Using the Example of "Hard Finishing"
331(4)
15.4 Process Chain Layout Using the Example "Gear Production"
335(6)
15.5 Process Supervision
341(4)
15.6 Questions
345(1)
References
346(3)
16 Surface and Subsurface Properties 349(22)
16.1 Surface Properties
350(5)
16.1.1 Determination of Surface Properties
351(4)
16.2 Subsurface Properties
355(13)
16.2.1 Determination of Subsurface Properties
356(6)
16.2.2 Effects of Cutting Processes
362(6)
16.3 Questions
368(1)
References
369(2)
17 Cooling Lubrication 371(26)
17.1 Requirements
371(2)
17.2 Cooling Lubricating Fluids
373(7)
17.2.1 Not Water-Mixable Cooling Lubricating Fluids
373(2)
17.2.2 Water-Mixable Cooling Lubricating Fluids
375(3)
17.2.3 Additivation of Cooling Lubricating Fluids
378(2)
17.3 Use of Cooling Lubricating Fluids in Geometrically Determined Cutting
380(3)
17.4 Use of Cooling Lubricating Fluid in Grinding
383(9)
17.4.1 Methods to Determine the Cooling Lubricating Fluid Effect in Grinding
385(2)
17.4.2 Applications and Effects
387(5)
17.5 Questions
392(1)
References
393(4)
18 Appendix 397
18.1 Solution to the Exercise for Chap. 3, Question 9
397(1)
18.2 Solution to the Exercise for Chap. 4, Question 26
397(1)
18.3 Solution to the Exercise for Chap. 5, Question 17
398(1)
18.4 Solution to the Exercise for Chap. 6, Question 25
399
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