Astakhov V. Tribology of Metal Cutting

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TRIBOLOGY OF METAL

CUTTING

TRIBOLOGY AND INTERFACE ENGINEERING SERIES

Editor

B.J. Briscoe (U.K.)

Advisory Board

M.J. Adams (U.K.) J. Israelachvili (U.S.A.)

J.H. Beynon (U.K.) S. Jahanmir (U.S.A.)

D.V. Boger (Australia) A.A. Lubrecht (France)

P. Cann (U.K.) I.L Singer (U.S.A.)

K. Friedrich (Germany) G.W. Stachowiak (Australia)

I.M. Hutchings (U.K.)

Vol. 27 Dissipative Processes in Tribology (Dowson et al., Editors)

Vol. 28 Coatings Tribology – Properties, Techniques and Applications in Surface

Engineering (Holmberg and Matthews)

Vol. 29 Friction Surface Phenomena (Shpenkov)

Vol. 30 Lubricants and Lubrication (Dowson et al., Editors)

Vol. 31 The Third Body Concept: Interpretation of Tribological Phenomena (Dowson et al., Editors)

Vol. 32 Elastohydrodynamics – ’96: Fundamentals and Applications in Lubrication

and Traction (Dowson et al., Editors)

Vol. 33 Hydrodynamic Lubrication – Bearings and Thrust Bearings (Frêne et al.)

Vol. 34 Tribology for Energy Conservation (Dowson et al., Editors)

Vol. 35 Molybdenum Disulphide Lubrication (Lansdown)

Vol. 36 Lubrication at the Frontier – The Role of the Interface and Surface Layers

in the Thin Film and Boundary Regime (Dowson et al., Editors)

Vol. 37 Multilevel Methods in Lubrication (Venner and Lubrecht)

Vol. 38 Thinning Films and Tribological Interfaces (Dowson et al., Editors)

Vol. 39 Tribological Research: From Model Experiment to Industrial Problem

(Dalmaz et al., Editors)

Vol. 40 Boundary and Mixed Lubrication: Science and Applications (Dowson et al., Editors)

Vol. 41 Tribological Research and Design for Engineering Systems (Dowson et al., Editors)

Vol. 42 Lubricated Wear – Science and Technology (Sethuramiah)

Vol. 43 Transient Processes in Tribology (Lubrecht, Editor)

Vol. 44 Experimental Methods in Tribology (Stachowiak and Batchelor)

Vol. 45 Tribochemistry of Lubricating Oils (Pawlak)

Vol. 46 An Intelligent System For Tribological Design In Engines (Zhang and Gui)

Vol. 47 Tribology of Elastomers (Si-Wei Zhang)

Vol. 48 Life Cycle Tribology (Dowson et al., Editors)

Vol. 49 Tribology in Electrical Environments (Briscoe, Editor)

Vol. 50 Tribology & Biophysics of Artiﬁcial Joints (Pinchuk)

Aims & Scope

The Tribology Book Series is well established as a major and seminal archival source for deﬁnitive books

on the subject of classical tribology. The scope of the Series has been widened to include other facets of

the now-recognised and expanding topic of Interface Engineering.

The expanded content will now include:

• colloid and multiphase systems; • rheology; • colloids; • tribology and erosion; • processing systems;

• machining; • interfaces and adhesion; as well as the classical tribology content which will continue to

include

• friction; contact damage; • lubrication; and • wear at all length scales.

TRIBOLOGY AND INTERFACE ENGINEERING SERIES, 52

EDITOR: B.J. BRISCOE

TRIBOLOGY OF METAL

CUTTING

VIKTOR P. ASTAKHOV

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First edition 2006

ISBN–13: 978-0-444-52881-0

ISBN–10: 0-444-52881-4

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0607080910 10987654321

CONTENTS

PREFACE ix

1. GENERALIZED MODEL OF CHIP FORMATION 1

1.1 Introduction 1

1.2 Inadequacy of the Single-Shear Plane Model 2

1.3 What is the Model of Chip Formation? 21

1.4 System Concept in Metal Cutting 23

1.5 Generalized Model of Chip Formation 23

1.6 Inﬂuence of Cutting Speed 43

1.7 Formation of Saw-Toothed Chip 48

1.8 Frequency of Chip Formation 53

1.9 Formation of the Segmental Saw-Toothed Chip 55

1.10 Applicability and Signiﬁcance of Chip Formation Models 60

References 62

2. ENERGY PARTITION IN THE CUTTING SYSTEM 69

2.1 Introduction 69

2.2 Energy Flows in the Cutting System 70

2.3 Physical Efﬁciency of the Cutting System 73

2.4 Determination of the Work of Plastic Deformation in

Metal Cutting 76

2.5 Practical Analysis of the Physical Efﬁciency of the

Cutting System 91

2.6 Energy Balance of the Cutting System 94

vi Contents

2.7 Methods of Improving Physical Efﬁciency of the

Cutting System 98

References 120

3. TRIBOLOGY OF THE TOOL–CHIP AND TOOL–WORKPIECE

INTERFACES 124

3.1 Introduction 124

3.2 Tool–Chip Interface 125

3.3 Tool–Workpiece Interface 177

3.4 Temperature at the Interfaces 189

References 211

4. CUTTING TOOL WEAR, TOOL LIFE AND CUTTING

TOOL PHYSICAL RESOURCE 220

4.1 Introduction 220

4.2 Known Approaches 221

4.3 Proper Assessment of Tool Wear 224

4.4 Optimal Cutting Temperature – The First Metal Cutting Law 227

4.5 Inﬂuence of Cutting Feed and Depth of Cut 239

4.6 Inﬂuence of Tool Geometry 245

4.7 Inﬂuence of Workpiece Diameter 248

4.8 Plastic Lowering of the Cutting Edge 254

4.9 Resource of the Cutting Wedge 269

References 274

5. DESIGN OF EXPERIMENTS IN METAL CUTTING TESTS 276

5.1 Introduction 276

5.2 DOE in Machining: Terminology and Requirements 277

5.3 Screening Test 281

5.4 2

Factorial Experiment, Complete Block 294

5.5 Group Method of Data Handling 307

References 323

6. IMPROVEMENTS OF TRIBOLOGICAL CONDITIONS 326

6.1 Cutting Fluids (Coolants) 327

6.2 Coatings 372

6.3 Improving Tribological Conditions by Modiﬁcation of

Properties of the Work Material 379

References 386

Contents vii

APPENDIXA BASICS, DEFINITIONS AND CUTTING TOOL

GEOMETRY 391

A1 Basic Terms and Deﬁnitions 391

A2 Reference Planes 394

A3 Angles: Deﬁnitions 396

A4 Determination of Uncut Chip Thickness for a General Case 410

References 413

APPENDIX B EXPERIMENTAL DETERMINATION OF THE CHIP

COMPRESSION RATIO (CCR) 414

B1 General Experimental Techniques 414

B2 Design of Experiment 416

INDEX 419

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