Klocke F. Manufacturing Processes 1: Cutting
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Subject Index 501
Manufacturing costs, 110, 279, 342–346, 349
equation, 343
Manufacturing disturbances, 3–8
randomly occurring, 3–4
systematic occurring, 3, 10
Martensite, 100–101, 108–109, 250, 252, 256,
260–262, 267, 269, 272, 275–277,
290
Material laws, 201–204
Material measures, 9, 13, 19
Measurement errors, 9–10, 363, 371
Measuring, 5, 8–24, 27–30, 36–37, 64, 66–67,
355, 359–363,
365, 369–370
Measuring instruments
dial comparator, 16, 21
dial gauges, 16, 21
with electrical converters, 17–18
electronic, 21
indicating, 9, 14–21
measuring microscopes, 17
mechanical callipers, 15
with mechanical converters, 15–17
micrometers, 15–16, 37–38, 126, 137, 149,
174
with optical converters, 18–19
with pneumatic converters, 19–21
Microcinematography, 53
Milling
contact conditions, 393, 411
down, 296, 304–306, 308–309, 324, 330,
391, 393, 400–401
resultant force, 362, 396–397, 412
secondary cutting edge, 328, 330
up, 304
–305, 308, 330, 391–394, 400–401
Minimum undeformed chip thickness, 391
Minor cutting edge, 41, 46, 56, 70, 78, 85–88,
125, 175, 184, 245, 272, 279, 320,
322, 385–386, 391, 395, 399, 431,
435, 449
Mixed ceramics, 96, 98, 162–167, 169, 171,
267, 271–272, 283, 395, 452
Model representation of shear plane, 87–88
M
OHR’s slip theory, 92
Molybdenum, 101, 103, 117, 120, 158, 254,
267, 276, 299, 315, 423
N
Nickel, 82, 86, 99, 107, 110–111, 115, 162,
169, 171–172, 181–182, 184, 251,
255, 267, 269, 274–276, 293–294,
300, 304, 307, 311, 312–327, 369
Nitriding steel, 433
Nitrogen, 108–109, 114, 117, 124, 126, 132,
152
–154, 156, 158, 172, 180, 251,
264, 268, 276, 302, 309
Non-ferrous metal
aluminium alloys, 178–179, 235,
290–293
copper alloys, 224, 311–315
magnesium alloys, 293–296
magnesium wrought alloys, 293
nickel alloys, 300, 314–315
titanium alloys, 107, 296–311, 325
Non-metal
aramid fibres, 332, 337
carbon fibres, 332, 334
fibre-reinforced plastics, 119, 156, 179,
327, 331–337, 395
graphite, 99, 155–156, 158–159, 166,
173, 177–181,
211, 280, 282–291,
327–331, 395
polymer matrix, 331–333
thermosetting plastics, 332
Non-metallic inclusions, 78, 256, 285
Normalizing, 253, 258, 261
Notch wear, 85–86, 127, 170, 184, 277, 279,
320–323
O
One-chisel method, 65–66
Optimal-cost cutting speed, 344–349
Optimal-cost tool life, 348
Optimal value function, 342, 347–348
Optoelectronic path measurement systems, 21
Oxidation, 67, 75, 84–85, 95, 112, 119, 122,
127–128, 141, 152–155, 168, 172,
180,
276, 287, 297, 299–300, 316
P
Parallel cracks, 78–79, 394
Particle jet erosion, 329
Passive force, 5, 55–56, 58–59, 69–71, 175,
243, 272, 322, 396, 398, 424, 442
PCBN, 86, 165, 169–170, 182, 187–188, 194,
226, 267, 271, 282–283, 286, 288,
302, 318, 322, 395
tool materials, 165, 169, 267, 283, 286,
288,
302, 318
PCD tools, 178, 302
Peripheral milling, 11, 391–392, 400–401
Perlite, 250–256, 258–263, 266–267, 269–270,
280–282, 284–286, 288–289, 300
Perlite-ferrite structure, 289
Phosphor, 220–223, 248, 255, 263–264
Plain milling, 395, 401
502 Subject Index
Planing
face, 458–459
gear, 467
rack, 466–467
supporting rack, 467
Plastic deformation, 33–35, 48–49, 51, 73,
76, 78, 80, 86, 115, 168, 199–202,
209–210, 223, 245, 273–274,
278–279, 311, 322, 328, 366, 455
Plastomechanical processes, 48
Plunge milling, 324–325
Pneumatic measurement, 20–21
Polycrystalline diamond, 98, 159, 173,
175–179, 292, 295, 313, 329,
334
Precision hard turning, 274
Profile milling
form cutters, 404
gang milling cutter, 404
Pyrometer, 65–67, 319, 369–370
Pyrometry, 66
R
Rake face, 39–41, 45, 47–49, 56–58, 62–64,
69–70, 76–77, 79, 84–88, 93–94,
184–185, 194–195, 212, 214, 224,
240, 245, 247–248, 254, 272–273,
277, 285, 287, 289, 292, 294,
300–303, 306–
307, 313, 321, 329,
336, 340, 366, 406–408, 420, 463,
465
Ramping, 322–323
Recrystallization annealing, 259–260
Reference systems
tool-in-hand system, 42–44, 57, 384
tool-in-use system, 42–43, 57
Residual austenite transformation, 272
Residual stresses, 3, 7–8, 31, 33–37, 131,
133–136, 141, 147, 150–152, 154,
157, 201, 272, 305–306, 314
Resultant force, 49, 55–56, 58–59, 61,
90–91,
94, 238, 243–245, 249, 251, 267,
269–270, 272, 279, 282, 285,
288–289, 292, 295–296, 304,
313–314, 330, 355, 362, 367, 381,
396–397, 412, 424–425
components, 49, 55, 58–59, 61, 91, 289,
367, 424
Ribbon chip, 248, 273, 293, 314, 341
Roughness parameters
depth of the deepest profile valley, 24
greatest height of the profile, 24
height of the highest profile point, 24
mean roughness value,
24
total height of the profile, 24
S
Saw
bands, 439–440
tooth chip, 273
Scaling, 75, 84–85, 200, 223, 379–380
Segmented chip, 49, 51–52, 209–212,
289–290, 310
formation, 52, 210–211, 290
Set, 13–14, 198–199, 352, 437
Shaving
axis intersection, 456–457
axis intersection angle, 454–456
diagonal angle, 456–457
diagonal, 456–457
gear, 454–455
parallel, 456–457
pitch circle, 455–456
plunge, 457
soft, 454
tangential, 457
wheel, 104, 454–
457
Shear angle, 56, 88–94, 211
Shear bands, 50–51, 209–210
Side and face milling, 194, 395
Skive hobbing
centring, 411
heat treatment distortion, 411
protuberance, 411
reference profile III, 411
Slab milling, 391, 395, 397, 415
Slotting
chip flow, 389, 464
collision, 458, 460, 465–466
danger, 466
cross-section of undeformed chip, 80, 111,
286, 292, 306, 328–329, 339, 384,
401, 425–426, 445, 463–464
development of wear, 263, 267, 463
face shaping, 458–459
gear shaping, 459–466
wheel, 460–462
, 466
idling stroke, 458
internal gear, 447, 451, 459–461, 465–466
lifting movement, 458, 466
planing feed stroke, 457–467
return stroke, 458–460, 465–466
shaping tool, 459, 464
tools, 445–467
working stroke, 454, 458–460, 466
Soft annealing, 251, 256–259, 261, 267–269
Subject Index 503
Specific cutting force, 60, 243, 248, 265, 272,
313, 340, 397, 427
Steel
acid-proof, 263
case-hardened, 33, 168, 259, 263, 266–269,
395, 464
cold-working, 269
construction, 58, 187, 249–250, 443–444,
464
hardened, 13, 99, 119, 149, 171, 182–183,
210, 267, 271–274, 394–395, 446,
452
heat-resistant, 120, 274, 276
heat-treatable, 233, 259–261, 263,
267
–268
high-alloyed, 101, 105, 249
high-speed, 187, 269, 292, 394
low-alloyed, 249
machining, 154, 256, 259, 263–266, 310
nitriding, 433
non-alloyed, 269–270, 277
non-rusting, 251, 274–279
tool, 80, 85, 95–97, 99–110, 167, 240,
263, 269–270, 273, 434, 436, 440,
442–443, 458
Stick-slip, 50, 294
Stress-relief heat treatment, 298
Stylus instrument, 27–29
Subjective surface inspection, 26–27
Submicron grain cemented carbide, 96,
119
Substrate pretreatment, 161
Sulfidic inclusions,
264
Sulphur, 158, 220–221, 223, 248, 254–255,
263–269, 287, 312–314
Surface damage, 8, 72, 74, 302, 321
Surface inspection, 21–30
Surface layer, 31–33, 37, 82, 109, 136, 257,
268
Surface measurement
mechanical measuring methods, 27–29
optical measuring methods, 27, 29–30
Surface parameters, 22–26, 54
Surface quality, 9–10, 25, 54, 69–71, 76,
149, 175, 178–179, 184, 196, 216,
229, 235, 245–247, 251–255, 258,
263–264, 266–267, 269–271, 274,
279, 282, 285, 290, 292, 304–305,
310, 313–314, 317, 320, 322,
329–331, 333–334, 336–337, 339,
341, 367, 384, 386, 397, 399–400,
411, 413–414, 416, 424, 428, 431,
434–436, 446
, 449, 454–455
Surface rim zone, 31, 33–37
Surface roughness, 21, 25, 30, 54–55, 67, 238,
252, 265–266, 274, 289, 329, 333,
336, 341
T
Technical surfaces, 21, 30–31
Temperature change cracks, 79–80
Temperature distribution, 66, 68
Temperature fields, 62, 66, 79
Temperature measurement, 64–67, 369–370
Temperature tool life rotation test, 240
Tempering, 100, 105–106, 257, 260–261,
263–264, 266, 268, 270, 281
Testing
objective,
9
subjective, 9
Thermal energy, 61, 136
Thermocouple, 65–66, 230
Thermography, 66–67, 369
Thread milling, 235, 416, 437–438
Thread moulding, 233, 438–439
Titanium
alloys, 107, 210, 296–311, 325
alumnides, 51, 299–300, 310
Tool-in-hand system, 42–44, 57, 384
Tool-in-use system, 42–43, 57
Tool(s)
approach angle, 42, 44, 68–69, 254
cutting edge
angle, 43–47, 58, 88, 384, 398
inclination, 44–47, 59
designs, 184–193
solid tools,
185–186
holder, 174, 176, 181, 185, 188–189,
191–192, 215–216, 232, 248, 344,
361, 365, 367, 385, 423
bit, 185
included angle, 69–70, 78, 193, 340
life
behaviour, 237–337, 339, 346, 351
conditions, 237–240, 248
criterion, 195, 213, 238–242, 278, 286,
339, 341, 423
function, 242, 346
straight lines, 346
normal rake angle, 44–45, 47
orthogonal clearance angle, 45,
59, 330
orthogonal rake angle, 45, 56–57, 59,
62–63, 69–70, 78, 91, 192–193,
236, 247–248, 252, 266, 283, 320,
392, 408–409, 411, 419
504 Subject Index
Tool(s) (cont.)
preparation, 193–196
steels, 80, 85, 95–97, 99–110, 167, 240,
263, 269–270, 273, 434, 436, 440,
442–443, 458
Toroidal core method, 35
Total active energy, 61
Tribooxidation, 73–75, 321
Trochoid milling, 324
Tungsten, 37, 76, 81–83, 85, 96–98, 101–103,
111, 113–117, 119–120, 123–124,
129, 131, 141, 157, 175, 181
, 254,
423
Turning
centreless rough, 386
chaser, 387–388
circular, 390
copy, 193, 389
cross-section of undeformed chip, 80, 111,
286, 292, 306, 328–329, 339, 384,
401, 425–426, 445, 463–464
cylindrical circular, 386
cylindrical face, 385
cylindrical profile grooving, 388
depth of cut, 384, 386
face, 46, 169, 303, 385–386
feed, 383–384, 386–390
finish planing, 169
form, 193, 389–390
helical, 387–388
internal, 169, 390–391, 423
kinematic form, 389
nominal cross-section of undeformed chip,
384
non-circular, 389
–390
profile die, 387–388
profile, 388–389
rough, 80, 104, 122, 279, 302, 383, 386
thread, 122, 387–388
thread chasing, 387–388
thread die cutting, 101, 252, 268, 286,
387–388
tool approach angle, 42, 44, 68–69, 254
tools, 4, 85, 101–102, 104, 184–187, 254,
362, 365, 385–391, 413, 451
transverse face, 385
transverse parting off, 385
transverse profile, 388
transverse profile grooving, 388
undeformed chip thickness, 56, 58–61, 88,
207, 244–245, 384, 391–392, 394,
396, 446, 463
width of undeformed chip, 58–60, 62–63,
70, 94, 384, 440, 443
Turn milling
axially parallel, 413
facet formation, 413
orthogonal, 413
Two-chisel method, 66
Two-colour pyrometer, 67
Types of chip
continuous, 49, 70, 94, 184, 207–209, 289,
313
discontinuous, 49, 51, 248, 285, 288, 296,
301, 341
lamellar, 49–52, 78, 294, 296, 301–303,
321
segmented, 49, 51
–52, 209–212, 289–290,
310
U
Undisturbed manufacturing process, 341
V
Vanadium, 101, 103–104, 255, 267–268, 299,
312, 423
Visual inspection, 26
W
Wear
abrasion, 71–72, 75–76
adhesion, 73
breaking, 78
built-up edges, 76
causes of, 74–85
diffusion, 74
forms, 85–87
mechanisms, 71–74
notches, 87, 285, 320–322
plastic deformation, 73, 76, 80
surface damage, 74
temperature change cracks, 79–80
thermoshock cracks, 79–80
tool life rotation test, 240–243
tribooxidation, 73–74
Wedge angle, 39,
42, 44–45, 56, 69–70, 78,
101, 192
Wet machining, 235, 279, 308
White-light interferometer, 29–30
Working plane, 43–45, 56, 247, 384, 392, 396
of reference, 56
Workpiece rim, 30–37
X
X-ray and neutron diffraction, 36–37
Z
Zementite, 282