Smith G.T. Cutting Tool Technology: Industrial Handbook
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Appendix 15. (continued) Machine tool spindle analysis – trouble-shooting guide. [Courtesy of
Lion Precision]
.
Appendix 583
Appendix 16a. Typical polar plots – quick-nd charts. [Courtesy of Renishaw plc].
584 Appendix
Appendix 16b. Typical polar plot and resultant diagnostic print-out. [Courtesy of Renishaw plc].
Appendix 585
Graham T. Smith, MPhil (Brunel), PhD (Birmingham), C Eng, FIMechE, FIEE
(Formerly: Professor of Industrial Engineering, Southampton Solent University, UK)
Graham T. Smith started his engineering career in the
early 1960’s at a West Midlands company that manu-
factured precision automotive parts by drop forging
and pressing. He was trained in a large Die-shop in
a heavy toolmaking environment, becoming a fully-
skilled and qualied crasman. In the late 1960’s, he
moved to the London area and joined initially, an
aerospace company working as a prototype toolmaker,
then later precision Jig-boring at an optical toolmak-
ing company, while gaining a Full Technological Cer-
ticate in Production Engineering. In the mid-1970’s,
the author worked for an industrial consultancy unit
the: Materials Advisory Service, based at e Univer-
sity of Southampton, while studying for a post-gradu-
ate Certicate of Advanced Study in Metallurgical
Quality Control, which was then followed by a Master
of Philosophy degree in Machinability – both at Bru-
nel University. Later, while working as a lecturer in the
Mechanical Engineering Department at e University
of Birmingham, he completed a Doctor of Philosophy
degree in Machined Surface Integrity.
While working at the Southampton Solent Univer-
sity – in the 1990’s, the author was instrumental in set-
ting up a fully-industrialised Flexible Manufacturing
System, featuring an integrated range of turning and
machining centres, robotic handling and a CMM for
part quality assessment. e tooling was of the mod-
ular type and the machines equipped with adaptive
control, with each machine tool being equipped with
touch-trigger probing. At the time of its installation,
About the Author
this FMS plant was probably one of the most sophisti-
cated and advanced in any educational establishment
in the UK. For many years, the author also acted as a
consultant for an international cutting uid producer
and distributor – industrial ‘trouble-shooting’, as well
as undertaking many complex machinability short-
and long-term duration projects, for a range of indus-
trial and aerospace companies.
In the 1990’s the author was one of the three found-
ing members of the international conference on: La-
ser Metrology and Machine Performance, which has
now ‘visited’ numerous university venues within the
UK. Later, the author was both the originator and then
Chairman of the international conference on Industrial
Tooling, which until recently resided at Southampton,
but now is hosted by Mississippi State University. e
notable features of this conference was a large tooling-
based exhibition – run by the conference secretary: Dr
Guy Littlefair, plus a range of industrial-based tool-
ing and machine tool speakers, with some exceptional
pioneering researchers in the elds of: metal cutting;
surface integrity and metrology. Typical of these ‘Key-
note speakers’ which notably included such alumini
as Professors: Milton C. Shaw; Ranga Komanduri; E.
Brinksmeier; David J. Whitehouse; John T. Berry; plus
Dr M. Eugene Merchant – to name but a few.
Professor Smith has lectured widely within the UK
and across both Europe and North America, while he
continues to undertake industrial consultancy and Ex-
pert Witness litigation activities.
Subject Index
180° semi-circle entry cycle 206
90° quarter circle entry cycle 206
γ
-solid solution’ 488
A
A
bbés principle 439
A
bbott-Firestone curve 312
a
bsolute machining test 274
a
bsorption coecient (Kρc) 103
a
ccelerated cutting-tool wear test 272
a
ccuracy 518
a
ccurate and precise rst-o machining 246
a
cid/alkaline test 407
a
cme thread 155
a
coustic emissions (AE) 539
a
coustic emission sensor (AE) 347
a
ctive-suppression of vibration 127
a
daptive compensation system 453
a
daptive control 535
a
daptive control constraint (ACC) 321
a
daptive control optimisation (ACO) 535
a
daptive error compensation 453
a
daptive remeshing technique 357
a
djustable balancing ring 469
a
iry-point 437
a
llergic reaction 420
a
lternating ank 193
a
mortisation 110
a
mplitude parameter 312
a
nalysis of variance (ANOVA) 282
a
nisotropic, or isotropic surface 307
A
NOVA test 282
a
nti-foaming agent 396
a
pparent density 277
a
queous-based cutting uid 395
a
rbor 256
a
rc evaporation 17
a
rithmetic average (AA) 133, 312
a
rithmetic mean roughness (Ra) 313
a
rithmetic progression 277
a
rithmetic roughness Ra parameter 133
a
rtefact stereometry 486
a
rticial intelligence 531
A
I and neural network integration 538
a
rticial neural networks (ANN) 539
a
sperities 315
a
stigmatism 528
a
symmetric drill head 116
atomic
d
iusion process 335
l
evels of resolution 516
r
adius 530
a
ttribute sampling 264
a
ttrition wear 77
a
utocollimation 453
axial force
c
omponent 82
a
xial force (F) 41, 101
B
B
-spline 502, 504
b
ack-lash 155
e
liminator 155
b
ack-taper 520
b
ack rake angle (α) 299
b
ack spot-facing 145
bacteria
c
ount 417
l
evel 417
bacteriological
e
ect 416
t
est method 407
balanced
m
odular tooling 230
tu
rning 291
b
alk-failure 115
–
–
–
–
–
–
–
–
–
–
–
–
ball-nosed slot-drill 153
ball bearing spindle design 440
b
allistic cutting speeds 432
b
eilby layer 362
b
ell-mouthing 135
e
ect 94
b
eta-function 324
b
ird nest 82
b
ird nesting 193
b
lack, or mixed ceramic 22
b
lock 450
p
rocessing time 449
t
ool system 219
boring bar
d
eection 131
s
election 122
b
oring tool technology 117
b
rinelling 230
b
uilding-up the tool le 242
b
uilt-up edge (BUE) formation 335
b
ulk hardness 273
b
ursting-pressure 480
C
c
anned cycle 75, 277
c
arbon entrapment 488
care, handling, control and usage –
o
f cutting uid 409
c
atastrophic, or tertiary wear 339
c
emented carbide 8
c
ementite 488
c
entre line average (CLA) 312
c
eramic and cermet 19
c
ermet 22, 23
c
oated 23
c
hamfer 36
c
hasing a thread 200
c
hatter 74, 117, 297
a
nd chip formation 297
a
nd vibration prediction 357
i
n machining operation 294
c
hemical composition test 273
c
hemically aected layer (CAL) 360
c
hemical vapour deposition (CVD) 14
c
hevron error 528
c
hilled cast iron surface 156
c
hilled compressed air 427
c
hilling-eect 522
chip-breaker
w
ear 79
chip-breaking
e
nvelope 76
–
–
–
–
–
–
–
–
–
–
–
t
echnology 66
c
hip-development 54
c
hip-evacuation/-exhaust 157
c
hip-ow 77, 88
a
nalysis 355
c
hip-gusset 155
c
hip-hammering 71
c
hip-pocket 155
c
hip-steaming 76
c
hip-thinning strategy 166
c
hip morphology 75
c
hip thickness 69
r
atio 56
c
hloroparan 418
c
hristmas tree routine 172
c
ircular interpolation 301
c
lamping force 509
classication
o
f cemented carbide tool grade 12
o
f tool wear type 334
c
learance angle – reduction (γ) 299
C
NC processing speed 449
coecient
o
f elasticity 127
o
f friction 353
o
f thermal expansion 525
c
ompatibility test 407
c
omplex machining: of sculptured surface 496
c
omposed radial and pendulum play 139
c
omposite-lling– machine tool base 509
c
ompressive chip thickness 56
c
omputer-aided design (CAD) 223
c
omputer-aided product development 398
c
omputerised-tool management 264
c
omputer numerical control (CNC) 51
c
onduction 101
c
onical error 528
c
onsolidation 4
c
onstant-pressure test 272
c
onstant chip-load 537
c
onstant surface speed 75, 280
c
ontinuous chip 56
w
ith a built-up edge (BUE) 58
c
ontinuous improvement program 242
c
ontour-tracking tool/workpiece measurement 252
c
onvection and radiation 101
c
ore-drilling 135
c
orrection of hole abnormality 118
corrosion
i
nhibitor 396
p
rotection 390, 416
c
oulomb 353
–
–
–
–
–
–
–
–
–
–
–
590 Subject Index
counter-boring 142
trepanning 107
c
ountersinks 142
c
ouple unbalance 469
c
rack initiation 368
c
rater wear 334
creating a tool management and document
d
atabase 240
c
reep 368
c
ritical cooling velocity 488
c
ross-honing 313
c
ross-talk 345
c
ubic boron nitride (CBN) 25, 30, 507
c
usp 64
c
ustomised drilling 110
customised milling
c
utter tooling 177
c
ut-o 308
c
ut-to-cut time 215
c
utter location source le (CLSF) 505
cutting
p
arameter – decision 123
c
utting-unit system 216
c
utting data 49
c
utting edge chipping 337
cutting uid
b
ased health issue 420
c
lassication 398
m
ist 422
qu
ality control 404
t
esting 414
c
utting force 201
d
ynamometry 343
c
utting force (∆Fc) 105
cutting insert
e
dge preparation 36
s
hape 105
c
utting speed 200
c
utting stiness (Ks) 297, 299
c
utting time 341
c
utting tool condition monitoring 531
c
utting toolholder/insert selection 43
c
ycle-time 150
c
ylindricity 135, 492
D
d
atum 110
d
eck of cards principle 53
d
eep-hole drilling 96, 113, 117
d
egraded tool test 272
d
egree of freedom 128
d
elay mark 206
–
–
–
–
–
–
–
–
–
–
–
d
eparture from roundness 135
d
epth of cut 299
d
esign of machinability test 270
d
iamond-like CVD coating 14
d
ie-cavity machining 498
d
ie and mould milled surface texture 498
d
ierentially-pitched 472
d
iusion wear 334
d
ilution control 414
d
imensionality 541
d
irectionality of the grain-ow 206
d
irect numerical control (DNC) 51
d
irect sensing 532
d
iscontinuous chip 60
d
islocation 374
m
ovement 488
d
isplayed prole 135
d
isposal of cutting uid 417
D
NC-link 234
d
ouble-negative cutting edge 156
d
ouble-positive cutting edge 156
d
ouble-tube ejector 115
d
own-cut milling 154
d
own-time 233
d
rill bushing tolerance 116
d
rilled hole slope angle 94
d
rilling 520
t
echnology 88
d
rive curve mill 505
d
runken thread 189
d
ry-machining 426
dual-contact
7
/24 taper system 465
t
ool 465
d
ual-plane balance 478
d
well mark 449
d
ynamic-balancing 474
d
ynamic balance of toolholding assemblies 467
d
ynamics of twist drilling hole 96
d
ynamic stiness 74, 509
d
ynamic system 344
d
ynamic unbalance 230, 471
d
ynamometry 532
E
e
ccentric machining 118
e
conomical tool life (Te) 342
economics of: dry-; near-dry and wet-
m
achining 427
edge
c
lamping system 45
f
rittering 160
–
–
–
–
–
–
Subject Index 591
rounding 36
eective entering angle 45
eect of servo-lag
a
nd gain on corner milling 448
a
nd gain whilst generating circular path 448
e
lastic distortion at contact 223
e
lectrostatic precipitator 423
e
limination of manual setting error 246
e
mulsication of tramp-oil 395
e
mulsier 396
e
mulsion 387
uid 398
e
nd-cutting edge angle 317
e
ndocrine hormone 418
e
ntry-cycle 206
e
rror 301
e
rror-back-propagation algorithm 539
e
thanol 522
E
uclidean error 541
E
ulerian technique 357
e
utectic steel 488
e
volution of cutting tool material 7
F
f
ace milling 151
e
ngagement 160
f
acing 34
o
peration 34
f
atigue 307, 336
f
eed and DOC 200
f
eed per tooth 166
f
eedrate 39
F
ibre-bed system 423
F
ick’s 1st law 334
F
ick’s 2nd law 334
nes 226
nite element analysis (FEA) 223, 305, 355
nite element method (FEM) 328
ank
i
nfeed 193
w
ear 64, 334
ash-point 423
oated-reaming 139
oating reaming 139
ood coolant 515
oor vibration audit 530
ow
s
tress 297
z
one 354
uid machining strategy: dry; near-dry; or wet 425
ute design 105
–
–
–
–
–
–
–
–
–
–
uteless tap 189
y-cut milling 150
f
oaming property 390
f
orce and temperature 357
f
orced vibration 295
f
orm error 528
f
orming 34
f
ractionation 392
f
racture 337
m
echanic 336
f
ree vibration 295
f
rictional condition 539
f
rictional eects during machining 353
f
rittering 94
f
ront-and back-end 223
f
rustum-based face-mill 175
f
ull-form 200
f
ully-automatic measurement of contour radii 252
G
g
ain 299, 448
g
alling 185
g
alvanic corrosion 396
g
ang-milling 259
g
as-spring support 453
g
auge line 223, 453
g
rooving and recessing 71
g
roup technology 241
g
un-, or deep-hole drill 103
g
un-drill 113
f
ailure 115
r
igidity rule 115
g
un-drilling 96, 113
H
h
-value 165
h
and-reamer 135
h
and and machine tap 182
h
and tap 182
h
ard-balancing 469
h
ard-milling – tool selection and replacement 514
hard-part
m
achining 128, 507
m
illing 511
tu
rning 508
h
ardness 507
h
armonic 126
r
oundness 287
health and safety factors – concerning cutting uid
o
peration and usage 418
h
eat aected layer (HAL) 360
–
–
–
–
–
–
–
592 Subject Index
helical 96
chip formation 71
c
utter 259
i
nterpolation 203
w
andering 94
h
elix angle 155
h
igh-eciency particulate air lter 423
h
igh-feed insert 66
h
igh-pressure cooling (HPC) 386
h
igh-pressure jet-assisted coolant delivery 383
h
igh-speed machining (HSM) 408, 432
h
igh-speed stee 507
h
igh static and dynamic rigidity 230
h
igh torque transmission 230
H
irth gear-tooth coupling mechanism 221
h
istorical development of cutting uid 382
h
istory of machine tool development 50
h
m value-range 165
h
omogeneity of material 272
h
oop-stress 287
h
ot hardness 6, 335
H
ot Isostatic Pressing (HIP) 8
H
SK dual-contact tooling 466
HSM
c
hucks – for turning operation 462
d
ynamic balancing machine application 472
m
achine tool design consideration 434
p
roblem of tool balance 469
r
esearch application 474
r
otating dynamometry 493
t
oolholders/chucks 458
with non-orthogonal machine tools and
r
obots 451
HSM dynamics
a
cceleration and deceleration 445
s
ervo-lag 446
HSS tool
m
aterial 272
w
ear-rate test 274
H
SS twist drill 107
h
uman body 530
h
uman skin 397
h
ybrid parameter 312
h
ybrid spindle 445
h
ydro-static bearing 509
p
erformance 511
h
ydrodynamic wedge 387
h
ydrolytic stability 425
h
ysteresis 439
l
oop 344
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
I
i
deal cutting uid 387
i
n-cycle tool breakage detection 246
i
ncident light image processing 252
i
ncremental feeding 193
i
ndexable drill 103, 107
i
ndirect sensing 532
i
nduction-hardened surface 156
i
nitial, or primary wear 339
i
nsert geometry 71
i
nsert pocket 472
i
nsert shape 45
i
nsert size 47
i
nterface pressure 54
i
nterference t 462
i
nterference ratio 203
i
ntermittent cutting action 150
i
nternal thread milling 206
i
ntroduction to surface texture parameter 305
I
sosceles triangle 488
i
sotropic material 26
J
j
obber drill 94
j
ogging-down 245
ju
st-in-time (JIT) 234
K
K
anban 234
k
eyway positioning 256
k
inematic 301
K
noop indentor 29, 364
k
nurling 209
K
urtosis parameter (Rku) 315
L
l
ace cuts 514
l
ack of anity 6
Lagrangian FEA
m
achining model 357
s
imulation machining modelling 357
L
agrangian methods 356
L
anchester boring bar 128
l
and 36
L
ang’s chip-packing ratio 68
l
aser-controlled feedback 453
l
aw of friction 353
l
ay 307
l
ead 195
l
ead time 263
l
east squares reference circle (LSC1) 492
–
–
Subject Index 593
lengthening eect 101
lights-out machining environment 230
l
imit and t 264, 462
l
imit gauge 223, 264
l
ine-boring 133
l
inear plunging 206
l
ine of balance 263
l
obed-shape 287
l
obing 287
l
ocation and restraint 160
l
ogistic 238
l
ogistical information and knowledge 238
l
ongitudinal turning 34
l
ook-ahead 450
l
ooping 505
l
ubricity 395
M
M
2 HSS 8
m
achinability 270
s
trategy 280
m
achine checking gauge (MCG) 489
m
achine cleaning 411
m
achined cusp 36, 82
m
achined roundness 285
m
achined surface texture (Rt) 48, 305
m
achined surface topography 317
m
achine reaming 135
m
achine tap 186
m
achine tool 526
a
xis-orthogonality 287
c
ompatibility 390
c
onguration 408
m
onitoring technique 531
o
ptimisation 535, 537
machining and turning centre modular quick-change
t
ooling 221
m
achining centre 150
m
achining modelling and simulation 350
m
achining simulation – validation 357
m
achining temperature 326
m
agnetic ‘active’ spindle 440
m
aintenance of the uid 414
m
anufacturing process envelopes 324
m
arine propeller manufacture 434
m
artensite 488
m
ass eect 191
m
aterial ratio curve (Rmr) 315
m
aterial removal rate 498
m
aterial requirement planning (MRP) 234, 243
m
aximum allowable chordal deviation 449
m
aximum production rate (Tq) 342
–
–
–
–
–
–
m
easurement of a complete tool station 246
m
easuring-cut time 218
m
echanical advantage (MA) 224
m
echanical fatigue cracking 336
m
echanically aected layer (MAL) 360
m
eso-scale machining 524
m
etal-to metal contact 223
m
eter cut-o 308
m
icro-boring tool 523
m
icro-drill 520
b
ack-taper 520
m
icro-drilling toolholder 523
m
icro-machine tool 525
m
icro-machining 524
m
icro-mill 522
m
icro-milling 523
m
icro-structural change 360
m
icro-tooling 518
m
aterial 520
m
icrobiocide 397
M
icroHole™ 250
m
icrostructure test 273
mill/turn
c
entre 150
o
peration 177
m
illed concavity 168
m
illed roundness – interpolated diameter 301
m
iller indices 30
m
illing 150, 522
c
losed-angle face 169
milling cutter
a
pproach angle 158
d
ensity 162
g
eometry 155
m
illing thin-wall 170
m
illing thin base 172
m
ineral oil 392, 423
s
ynthetic, or semi-synthetic lubricant 392
m
inimum undeformed chip thickness 319
m
ixed-tipping 105
m
ode of deformation 101
m
odied ank infeed 193
m
odular quick-change tooling 212
m
odular tooling 118
monitoring, maintenance and testing of cutting uid
–
in use 411
m
onolithic diamond 530
m
orse taper 135
M
oS2 super-glide coating 19
mounting and adjusting
m
illing cutter 256
s
ingle-blade reamer 261
–
–
–
–
–
–
–
–
–
–
–
594 Subject Index