Klocke F. Manufacturing Processes 1: Cutting

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RWTH edition

RWTH Aachen

Fritz Klocke

Manufacturing Processes 1

Cutting

Translated by Aaron Kuchle

123

Professor Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Dr. h.c. Fritz Klocke

Laboratory for Machine Tools and Production Engineering

RWTH Aachen University

Steinbachstr. 19

52074 Aachen

Germany

f.klocke@wzl.rwth-aachen.de

Translated by

Aaron Kuchle

Yeungnam University

Korean Language Institute

214-1 Dae-dong Gyeongsan Gyeongbuk 712-749

Korea

aaronkuchle@yahoo.com

ISSN 1865-0899 e-ISSN 1865-0902

ISBN 978-3-642-11978-1 e-ISBN 978-3-642-11979-8

DOI 10.1007/978-3-642-11979-8

Springer Heidelberg Dordrecht London New York

Library of Congress C ontrol Number: 2011925556

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Preamble About Compendium “Manufacturing

Processes”

Key factors for quality and economic efﬁciency of industrial production are the

choice of the manufacturing processes and their design. Manufacturing Technology

is an elemental part of the fundamental knowledge of machining engineers. Also

design engineers have to gain knowledge in this ﬁeld, since they have high respon-

sibility for the manufacturing costs. However, the students as well as practising

experts who are willing to enhance their knowledge have the problem to collect

information. To the current day there is no extensive, but still clear description of

manufacturing processes focussing on the technology itself.

In order to counter this necessity the compendium at hand is supposed to present

an overall picture of the most common machining and non-machining manufac-

turing processes. Additional to the description of the techniques these volumes are

desired to deliver an insight in the underlying physical principles whenever it is

necessary for the understanding of the processes.

The apportionment of the compendium “Manufacturing Processes” into

Volume 1: Cutting

Volume 2: Grinding, Honing, Lapping

Volume 3: Electrical Erosion and Hybride Processes

Volume 4: Forming

Volume 5: Casting, Sintering, Rapid Prototyping

groups techniques with similar active principles together.

In front of the ﬁrst volume is placed a technique-spanning section to the toler-

ances and questions of the workpiece measuring techniques used in manufacturing.

Within the individual volumes was tried to avoid an encyclopaedic listing of the

techniques. The book series are primarily intended for junior scientists in the ﬁelds

of manufacturing technology and construction. In addition, the practitioner will be

able to refurbish or extend his knowledge. The variety of manufacturing problems

vi Preamble About Compendium “Manufacturing Processes”

is as large as the multiplicity of the products, and alone with text book wise sayings

manufacturing questions are not to be solved. We wish that this book offers starting

points and ways to its readers, on which they can come up with successful solutions

by engineering thinking.

Aachen, Germany Fritz Klocke

September 2010

Preamble for Volume 1 “Cutting”

The available volume treats machining with geometrically deﬁned cutting edges.

It approaches both the practical engineer and the student of engineering sciences.

This book is based on the lecture “Manufacturing Technologies I and II” and the

pertinent exercises, which are held at RWTH Aachen University. The arrangement

of the book results from the experiences, which were gained when lecturing in the

chronology of the course.

The structure of the book is oriented to a large extent at didactical criteria. The

ﬁrst section deals with the metrology and the workpiece quality, followed by a chap-

ter about the fundamentals of cutting. Based on the common technological principle

of the cutting processes and their variants, the second section deals with the mech-

anisms occurring at the cutting edge and the resulting loads on the tools. The next

section deals with the demands on the cutting materials as well as their manufac-

turing processes and application. The text presents topics like the use of the ﬁnite

element method for cutting processes as well as cutting ﬂuids. A detailed chapter

about the machinability of the most important work piece materials, such as steel

and cast iron, light metal alloy and high temperature resistant materials imparts a

broad knowledge of the alternating coactions of work piece material, the cutting

material and the process parameters.

The necessity for process control, used sensor systems and application possi-

bilities are regarded. Due to the increasing relevance and application in industrial

manufacturing plants, monitoring systems are discussed in their own chapter.

Finally, the different cutting processes and their kinematic characteristics are

presented in detail.

For their cooperation with the compilation of the available edition I would

like to thank my co-workers, Dr.-Ing. M. Abouridouane, Dr.-Ing. K. Gerschwiler,

Dipl.-Ing. M. Arft, Dipl.-Ing. C. Essig, Dipl.-Ing. P. Frank, Dipl.-Ing. A. Krämer,

Dipl.-Ing. D. Lung, Dipl.-Ing. H. Sangermann, Dipl.-Ing. R. Schlosser, Dipl.-Ing.

vii

viii Preamble for Volume 1 “Cutting”

P. Vogtel, as well as Dipl.-Ing. S. E. Cordes, who was additionally responsible for

the coordination of the work on this book.

Further I would like to thank the many former co-workers, who participated in

the past German editions and now have leading positions in industry and research

companies.

Aachen, Germany Fritz Klocke

September 2010

Contents

1 Introduction ............................... 1

2 Metrology and Workpiece Quality .................. 3

2.1 Manufacturing Disturbances and Manufacturing History .... 3

2.2 MeasuringandTesting...................... 8

2.2.1 MeasurementErrors .................. 9

2.2.2 Macro- and Microgeometry of Components . . .... 10

2.3 Length Testing Devices ...................... 13

2.3.1 MaterialMeasures ................... 13

2.3.2 Gauges . . ....................... 13

2.3.3 IndicatingMeasuringInstruments ........... 14

2.4 SurfaceInspection ........................ 21

2.4.1 SurfaceParameters................... 22

2.4.2 Subjective Surface Inspection ............. 26

2.4.3 SurfaceMeasurement.................. 27

2.5 InspectionoftheWorkpieceRim ................ 30

2.5.1 Surface Layers . . . .................. 31

2.5.2 InspectionoftheSurfaceRimZone .......... 33

3 Fundamentals of Cutting ........................ 39

3.1 The Cutting Part – Concepts and Terms ............. 39

3.2 Reference Systems . ....................... 42

3.3 Basic Process Variants ...................... 45

3.4 ChipFormation.......................... 47

3.4.1 The Cutting Process .................. 47

3.4.2 Different Types of Chip Formation . . . ........ 49

3.5 Kinematic Surface Roughness .................. 54

3.6 Mechanical and Thermal Strain on the Cutting Section . .... 55

3.6.1 Inﬂuence of the Geometry of the Cutting Section . . . 68

3.7 Wear ............................... 71

3.7.1 Wear Mechanisms . .................. 71

3.7.2 CausesofWear..................... 74

3.7.3 FormsandDimensionsofWear ............ 85