Professional Documents
Culture Documents
Fundamentals of Machining and Machine Tools Second Edition PDF
Fundamentals of Machining and Machine Tools Second Edition PDF
Fundamentals of Machining and Machine Tools Second Edition PDF
Second Edition
Geoffrey Boothroyd
Winston A. Knight
www.Technicalbookspdf.com
ISBN: 0-8247-7852-9
First edition copyright 1975 by Scripta Book Company (McGraw-Hill, Inc.)
Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical,
including photocopying, microfilming, and recording, or by any information storage and retrieval system, without
permission in writing from the publisher.
www.Technicalbookspdf.com
i
Preface
This book is intended primarily for those studying and teaching the principles of machine tools and metal machining in
universities and colleges. It should also prove useful to those concerned with manufacturing in industry.
The mathematical content of the book is deliberately limited. Those who have taken basic courses in statics and
dynamics and who have had an introduction to calculus should have no difficulty in comprehending the material.
Many of the present texts dealing with the same material are purely descriptive. In this book, the approach is to
illustrate, through fundamentals and analysis, the causes of various phenomena and their effects in practice. Emphasis is
given to the economics of machining operations and the design of components for economic machining.
A significant portion of the book is based on a previous text written by one of the authors (Geoffrey Boothroyd) and
published by McGraw-Hill. While much of this material has been retained, recent developments have been included
where appropriate. Several new chapters have been introduced and others largely rewritten. The section on tool
materials has been expanded to include the modern materials that are contributing significantly to increases in
productivity in industry. A new chapter on
New emphasis in the book has been placed on the utilization of machine tools through the inclusion of chapters on
manufacturing systems and automation and on computer-aided manufacturing, together with an expanded chapter on
design for machining, which serves as an introduction to an area of growing importance, that of design for
manufacturability. Various types of automation in machine tools are outlined and an introduction to cellular plant
layouts and flexible manufacturing systems is included. Aspects of the programming of numerical control machine tools
are discussed in some detail. Finally, because of their growing importance, the main nonconventional machining
processes are described and examples of their application given.
We are indebted to those with whom we have been associated in recent years and who have assisted both directly and
indirectly in the preparation of this book, including colleagues and graduate students whose work has been helpful in the
preparation of this book. Finally, we would like to thank Ms. Kathleen Yorkery for typing the manuscript.
GEOFFREY BOOTHROYD
WINSTON A. KNIGHT
Preface iii
xi
Standardization
xiv
Introduction to the International (SI) System of Units
1 1
Machine Tools and Machining Operations
1
1.1 Introduction
2
1.2 Generating Motions of Machine Tools
5
1.3 Machines Using Single-Point Tools
26
1.4 Machines Using Multipoint Tools
47
1.5 Machines Using Abrasive Wheels
58
1.6 Summary of Machine Tool Characteristics and Machining Equations
66
Problems
71
Reference
f
www.Technicalbookspdf.com
2 73
Mechanics of Metal Cutting
73
2.1 Introduction
75
2.2 Terms and Definitions
77
2.3 Chip Formation
81
2.4 The Forces Acting on the Cutting Tool and Their Measurement
82
2.5 Specific Cutting Energy
83
2.6 Plowing Force and the "Size Effect"
86
2.7 The Apparent Mean Shear Strength of the Work Material
90
2.8 Chip Thickness
99
2.9 Friction in Metal Cutting
104
Problems
107
References
3 109
Temperatures in Metal Cutting
109
3.1 Heat Generation in Metal Cutting
110
3.2 Heat Transfer in a Moving Material
112
3.3 Temperature Distribution in Metal Cutting
121
3.4 The Measurement of Cutting Temperatures
www.Technicalbookspdf.com
125
Problems
127
References
4 129
Tool Life and Tool Wear
129
4.1 Introduction
130
4.2 Progressive Tool Wear
130
4.3 Forms of Wear in Metal Cutting
140
4.4 The Tool Material
148
4.5 The Work Material
151
Problems
152
References
5 155
Cutting Fluids and Surface Roughness
155
5.1 Cutting Fluids
156
5.2 The Action of Coolants
156
5.3 The Action of Lubricants
163
5.4 Application of Cutting Fluids
166
5.5 Surface Roughness
www.Technicalbookspdf.com
page_vii
Page vii
173
Problems
173
References
6 175
Economics of Metal-Cutting Operations
175
6.1 Introduction
177
6.2 Choice of Feed
178
6.3 Choice of Cutting Speed
182
6.4 Tool Life for Minimum Cost and Minimum Production Time
184
6.5 Estimation of Factors Needed to Determine Optimum Conditions
185
6.6 Example of a Constant-Cutting-Speed Operation
188
6.7 Machining at Maximum Efficiency
191
6.8 Facing Operations
194
6.9 Operations with Interrupted Cuts
195
6.10 Economics of Various Tool Materials and Tool Designs
200
6.11 Machinability Data Systems
200
Problems
204
References
7 205
Nomenclature of Cutting Tools
www.Technicalbookspdf.com
page_vii
205
7.1 Introduction
207
7.2 Systems of Cutting-Tool Nomenclature
213
7.3 International Standard
223
Problems
224
References
8 225
Chip Control
225
8.1 Introduction
226
8.2 Chip Breakers
230
8.3 Prediction of Radius of Chip Curvature
234
8.4 Tool Wear During Chip Breaking
237
Problems
237
References
9 239
Machine Tool Vibrations
239
9.1 Introduction
240
9.2 Forced Vibrations
www.Technicalbookspdf.com
page_viii
245
9.3 Self-Excited Vibrations (Chatter)
264
9.4 Determination of Frequency Response Loci
269
9.5 Dynamic Acceptance Tests for Machine Tools
270
9.6 Improving Machine Tool Stability
277
Problems
279
References
10 281
Grinding
281
10.1 Introduction
281
10.2 The Grinding Wheel
286
10.3 Effect of Grinding Conditions on Wheel Behavior
290
10.4 Determination of the Density of Active Grains
290
10.5 Testing of Grinding Wheels
290
10.6 Analysis of the Grinding Process
303
10.7 Thermal Effects in Grinding
307
10.8 Cutting Fluids in Grinding
308
10.9 Grinding-Wheel Wear
311
10.10 Nonconventional Grinding Operations
www.Technicalbookspdf.com
page_viii
315
Problems
315
References
11 317
Manufacturing Systems and Automation
317
11.1 Introduction
318
11.2 Types of Production
319
11.3 Types of Facilities Layout
321
11.4 Types of Automation
324
11.5 Transfer Machines
328
11.6 Automatic Machines
331
11.7 Numerically Controlled (NC) Machine Tools
338
11.8 Comparison of the Economics of Various Automation Systems
339
11.9 Handling of Components in Batch Production
340
11.10 Flexible Manufacturing Systems
350
Problems
351
References
12 353
Computer-Aided Manufacturing
353
12.1 Introduction
354
12.2 Scope of CAD/CAM
www.Technicalbookspdf.com
page_viii
356
12.3 Process-Planning Tasks
www.Technicalbookspdf.com
page_x
Page x
514
Problems
514
References
Nomenclature 517
Index 531
Page 531
Index
Abrasive wheels, 47
Area of contact,
apparent, 101
real, 159
multispindle, 328
single-spindle, 328
Automation, 317-51
fixed, 322-3
Page 532
metallic, 285
resinoid, 285
rubber, 285
shellac, 285
silicate, 285
vitrified, 285
Boring, 11, 15
Boring bar, 20
horizontal 19-20
Broaching machine, 43
CAD, 353
CAD/CAM, 354-5
CAM, 353-97
Carbide
coated, 146
titanium, 145
tungsten, 145
brazed, 135
Carriage of a lathe, 5
Center drilling, 32
Chip, 2, 73
discontinuous, 80
length of, 88
Chips
overbroken, 230
underbroken, 230
types of
ribbon, 226
spiral, 226
straight, 226
tubular, 226
Page 533
undeformed, 10
Chuck, 5, 15
CIM, 356
Collet, 16
Contact
with built-up-edge, 80
Coolants
Costs
major, 10
tool 217
working, 217
tool, 217
working, 217
Cutting fluids
flood, 165
manual, 165
mist, 165
in grinding, 307-9
Cutting force, 81
Page 534
Cutting speed, 9
Cylindrical turning, 7, 11
Data base
machinability, 200
Deformation zone
Depth of cut, 10
in milling, 36
Dies, 45
Discontinuous chip, 80
Dog, 16
Drilling, 27
center, 32
Face of tool, 8, 75
Face plate, 16
Facing, 11, 14
Feed, 7
Feed motion, 3, 7, 9
Feed speed, 9
Flank of tool, 8, 76
AGVs, 347
Form cutting, 38
Frequency response
cross, 345
direct, 345
Friction
angle, 102
force, 101
in metal cutting, 99
Grains, 281
Grinding, 281-316
Page 536
plunge, 49, 56
cylindrical 296
flooding, 308
Grinding machine
cylindrical, 55-7
internal, 57-8
Hardness,
Headstock, 5
coated, 143
ISO
Page 537
Lathe
single-spindle, 328
multispindle, 328
carriage of, 5
engine, 5-11
turret, 19
types of operation, 11
Lubrication
boundary, 156-9
Machined components
Machined surface, 11
Machine tools
automatic, 328-30
axes of, 3
Machining
definition of, 5
Machining time
in broaching, 43
in drilling, 28
in face milling, 41
of lathe, 7
in milling, 87
in plunge grinding, 51
of shaper, 23
in traverse grinding, 50
flexible, 342
Page 538
Metal cutting
friction in, 99
in broaching, 44
in cylindrical grinding, 56
in drilling, 28
in grinding, 293
in milling, 38
of shaper, 23
in traverse grinding, 49
in turning, 12
in vertical milling, 38
Milling
angular, 39
face, 40
gang, 39
straddle, 39
Milling machine
horizontal, 33-40
Modes of vibration
natural, 245
Multi-point tools, 26
NC, 323-4
NC machines, 331-8
NC motions, 333-5
linear, 333
point-to-point, 333
positional, 333
NC processor, 375
NC programming
APT-based, 380-87
locus, 258
Page 539
diamond, 147
Postprocessor, 375
Primary motion
of machine tools, 2
of tool, 8
Production
Productivity, 317
Rake
Rake angle, 76
Reaming, 32
Receptance
cross, 259
Regrindable tools
Resonance, 241
Start of Citation[PU]Marcel Dekker, Inc.[/PU][DP]1989[/DP]End of Citation
Page 540
angle of, 9
Screw cutting, 15
Shear angle, 87
Shear plane, 87
corner of, 8
Slab milling, 33
Slotting, 38
Spot facing, 33
Standardization, 400-1
Surface
ideal, 166
natural, 168
Tailstock of lathe, 5
Taps, 45
Taylor's tool life relationship, 134, 178, 183, 191-2, 326, 446
processing, 387-94
Page 541
Threading, 11, 15
Thrust force, 81
Time
nonproductive, 175
Tool
face of, 8, 75
flank of, 8
holder for, 7
post for, 7
Tool angles
Tool materials
ceramic, 147
cermets, 147
diamond, 147
coated, 143
flank, 131-2
Tools
ceramic, 147
cermet, 147
multipoint, 26
polycrystalline, 147-8
titanium-carbide, 145
tungsten-carbide, 145
flexible, 343
Transient surface, 11
Traverse, 49, 53
Turning
ponent, 455-7
Twist drill, 27
Vibrations
free, 239
self-excited, 240
transient, 239
Wear
abrasive, 130
adhesion, 130
criteria
flank, 131-2
Wear test
accelerated, 149
rapid, 149
Wedge angle, 76
Work engagement, 36
Work-in-progress, 319
Workpiece, 2
grinding, 293
Work surface, 11
Work-tool-thermocouple, 121-3