Geometry_of_Single_point_Turning_Tools_and_Drills

机器鼠

+ ?. Y/ b/ _) W5 Y9 D- w2 J* I1 J9 T
Geometry_of_Single_point_Turning_Tools_and_Drills__Fundamentals_and_Practical_Applications.pdf
: s9 d; E; ?8 ~; {有要的吗？刀具，细节，很到位。英文版。
国内无人这么细研究的吧？

狙击手

说什么的？

机器鼠

Although almost any book and/or text on metal cutting, cutting tool design, and
5 x: n' e; F5 ]; g! Xmanufacturing process discusses to a certain extent the tool geometry, the body of
2 ~, c2 W. n1 u: i, |1 Cknowledge on the subject is scattered and  confusing. Moreover, there is no clear
objective(s) set in the selection of the tool geometry parameters so that an answer
& r7 P$ ]4 F0 S/ T+ R/ Fto a simple question about optimal tool geometry cannot be found in the literature
* Y) l5 @1 u# l. fon the subject. This is because a criterion (criteria) of optimization is not clear, on
one hand, and because the role of cutting tool geometry in machining process
. |0 z% b3 d. eoptimization has never been studied systematically, on the other. As a result, many
practical tool/process designers are forced to use extremely vague ranges of tool
geometry parameters provided by handbooks. Being at least 20+ years outdated,
these data do not account for any particularities of a machining operation including
a particular grade of tool material, the condition of the machine used, the cutting
fluid, properties and metallurgical condition of the work material, requirements to
5 |# D* r% R0 y: Zthe integrity of the machined surface, etc.
$ K4 `+ j: ]. F# L8 U6 KUnfortunately, while today's professionals, practitioners, and students are
0 A* o4 l  r9 M$ rinterested in cutting tool geometry, they are doomed to struggle with the confusing
terminology. When one does not know what the words (terms) mean, it is easy to
* Y* {- D. J3 H4 v& Uslip into thinking that the matter is difficult, when actually the ideas are simple,
' C8 `, n( c" h4 h: b: X% L$ seasy to grasp, and fun to consider. It is the terms that get in the way, that stand as a
4 G7 m9 q% _6 h; ^# mwall between many practitioners and science. This books attempts to turn those
4 P4 P# X; ~# a- Swalls into windows, so that readers can peer in and join in the fun of proper tool
9 r2 t2 C7 z" L+ pdesign.
5 {* y( i! a5 [! |8 W# x% v: kSo, why am I writing this book? There are a few reasons, but first and foremost,
because I am a true believer in what we call technical literacy. I believe that
everyone involved in the metal cutting business should understand the essence and
( q; F- d9 k9 f6 p. Z6 S4 wimportance of cutting tool geometry. In my opinion, this understanding is key to
improving efficiency of practically all machining operations. For the first time, this
book presents and explains the direct correlations between tool geometry and tool
performance. The second reason is that I felt that there is no comprehensive book
8 }; N3 S7 e' J, son the subject so professionals, practitioners, and students do not have a text from
which to learn more on the subject and thus appreciate the real value of tool
8 U' v# L9 M  k" \8 M! \' A3 Z0 @/ egeometry. Finally, I wanted to share the key elements of tool geometry that I felt
  U+ C/ y' D5 j1 `5 S3 x* m9 _- P9 kwere not broadly understood and thus used in the tool design practice and in
optimization of machining operations in industry. Moreover, being directly
involved in the launch of many modern manufacturing facilities equipped with
state-of-the-art high-precision machines, I found that the cutting tool industry is not
ready to meet the challenge of modern metal cutting applications. One of the key
issues is the definite lack of understanding of the basics of tool geometry of
; \0 M- ~3 r9 K) d& ^standard and application-specific tools.
The lack of information on cutting tool geometry and its influence on the
$ W& o/ u9 ^6 c  f1 U, noutcome of machining operations can be explained as follows. Many great findings
$ {8 {) N' K6 c) _) lon tool geometry were published a long time ago when neither CNC grinding
3 z% {+ F; Y/ ^% xmachines capable of reproducing any kind of tool geometry were available nor
2 z' b% f/ Q( J( b+ D8 ]3 }were computers to calculate parameters of such geometry (using numerical
0 d, A$ G' W4 u9 ?& ?methods) common. Manual grinding using standard 2- and 3-axis simple grinding
3 f7 a' `2 B' t, m& \' Z  Lfeatures was common so the major requirement for tool geometry was the simpler
4 g. a5 g6 k5 \the better. Moreover, old, insufficiently rigid machines, aged tool holders and part
fixtures, and poor metal working fluid (MWF) selection and maintenance levered
! @9 W9 b8 ?- F* Q4 Wany advancement in tool geometry as its influence could not be distinguished under
these conditions. Besides, a great scatter in the properties of tool materials in the
past did not allow distinguishing of the true influence of tool geometry. As a result,
studies on tool geometry were reduced to  theoretical considerations of features of
twist drills and some gear manufacturing  tools such as hobs, shaving cutters,
shapers, etc.  
Gradually, once mighty chapters on tool geometry in metal cutting and tool
design books were reduced to sections of few pages where no correlation between
; y7 [8 q5 l4 ttool geometry and tool performance is normally considered. What is left is a
) C' a; L' B( y  Cgeneral perception that the so-called “positive geometry” is somehow better than
“negative geometry.” As such, there is no quantitative translation of the word
“better” into the language  of technical data although a great number of articles
written in many professional magazines discuss the qualitative advantages of
“positive geometry.” For example, one popular manufacturing magazine article
% d4 E" R# K, v) G1 a2 Hread “Negative rake tools have a much  stronger leading edge and tend to push
against the workpiece in the direction of the cutter feed. This geometry is less free
: W2 C5 g  w$ D1 l% Ucutting than positive rakes and so consumes more horsepower to cut.” Reading
* K  E, a, Y* D8 U0 P0 Ythese articles one may wonder why cutting tool manufacturers did not switch their
2 g) B4 \& x( Q; U6 k" f4 Qtool designs completely to this mysterious “positive geometry” or why some of
$ v, Q8 o. t; o/ c) x: y1 R$ Z9 H7 tthem still investigate and promote negative geometry.
During recent decades, the metalworking industry underwent several important
changes that should bring cutting tool geometry into the forefront of tool design
4 f0 O- ?/ |' ]) V! i* j! Aand implementation:

机器鼠

1   What Does It Mean “Metal Cutting”? ...........................................................1
1.1   Introduction ...............................................................................................1
5 r! D# K6 D5 U- e( G2 ]- f1.2   Known Results and Comparison with Other Forming Processes ..............2
  1.2.1   Single-shear Plane Model of Metal Cutting ...................................2
  1.2.2   Metal Cutting vs. Other Closely Related Manufacturing  
Operations .................................................................................................5
1.3   What Went Wrong in the Representation of Metal Cutting?...................22
  T7 N; r7 l. U' A/ S9 N  1.3.1   Force Diagram..............................................................................23
  1.3.2   Resistance of the Work Material in Cutting.................................25
  1.3.3   Comparison of the Known Solutions for the Single-shear  
* J) G: l# \$ f* f, i4 J  Plane Model with Experimental Results .................................................27
1.4   What is Metal Cutting?............................................................................28
, R( i4 }# F- }; L' _3 p# m1 l  1.4.1   Importance to Know the Right Answer........................................28
2 g) Z7 E! `2 W4 w* d1 s8 T 1.4.2  Definition .....................................................................................28
. H2 y" {" i! H0 M  1.4.3   Relevance to the Cutting Tool Geometry.....................................29
1.5   Fundamental Laws of Metal Cutting.......................................................32
  1.5.1   Optimal Cutting Temperature – Makarow’s Law........................32
1.5.2  Deformation Law.........................................................................35
0 V3 X( p, I+ T4 r, _& P1 fReferences........................................................................................................50
2   Basic Definitions and Cutting Tool Geometry,  
Single Point Cutting Tools ............................................................................55
1 F2 i) b9 m  E) r5 f2 ^1 K: a2.1   Basic Terms and Definitions ...................................................................55
2.1.1  Workpiece Surfaces.......................................................................57
4 Z1 o* r$ [3 S& k5 D) Z% Q 2.1.2  Tool Surfaces and Elements ..........................................................57
. x# t! k& w' }9 V4 t 2.1.3  Tool and Workpiece Motions.......................................................57
% S4 X, Z, z3 R' N+ r9 j( ` 2.1.4  Types of Cutting ............................................................................58
2.2   Cutting Tool Geometry Standards...........................................................60
( T* {: M# M5 b; I. g0 V2.3   Systems of Consideration of Tool Geometry ..........................................61
2.4.  Tool-in-hand System (T-hand-S) .......................................................64
  2.4.1   Tool-in-hand Coordinate System.................................................64
# t7 `, ]+ o/ @! l& i4 a+ b 2.4.2  References Planes ........................................................................66
& N+ R8 f. A! q5 L  D1 N 2.4.3  Tool Angles..................................................................................68
  2.4.4   Geometry of Cutting Tools with Indexable Inserts ......................74
+ E+ N# }0 S' `, d  h2.5   Tool-in-machine System (T-mach-S)......................................................84
2 l# C9 Z4 t0 p  J 2.5.1  Angles ..........................................................................................84
# Y- Q, _8 x, d# W6 Z7 P/ z  2.5.2   Example 2.3 .................................................................................88
2.6   Tool-in-use System (T-use-S) .................................................................90
- u# }3 O/ y; l 2.6.1  Reference Planes ..........................................................................91
2.6.2  The Concept .................................................................................92
  2.6.3   Modification of the T-hand-S Cool Geometry .............................92
5 Y+ {( M( Z1 s/ L! r8 }7 _  2.6.4   Kinematic Angles.........................................................................98
7 D  F1 W* g3 m8 {  2.6.5   Example 2.4 ...............................................................................100
2.7   Avalanched Representation of the Cutting Tool Geometry  
in T-hand-S............................................................................................102
# ~% O+ q- a) U( r* S, O2 w 2.7.1  Basic Tool Geometry .................................................................102
2.7.2   Determination of Cutting Tool Angles Relation
  ]8 Q% ~3 O* g4 v5 s9 [' ^# y  for a Wiper Cutting Insert ..........................................................108
  2.7.3   Determination of Cutting Tool Angles  
   for a Single-point Tool ...............................................................110
  2.7.4   Flank Angles of a Dovetail Forming Tool .................................117
  2.7.5   Summation of Several Motions..................................................119
) O) S- _! i5 U/ J1 j0 f& QReferences......................................................................................................125
5 |/ b, X% _0 u0 u# B3  Fundamentals of the Selection of Cutting Tool Geometry Parameters...127
! D0 r. x( Y2 P3.1   Introduction ...........................................................................................127
  M( U6 L2 J( W3.2   General Considerations in the Selection of Parameters  
  of Cutting Tool Geometry .....................................................................129
3.2.1 Known Results .............................................................................129
$ i  |$ u! @- N5 |  3.2.2 Ideal Tool Geometry and Constrains............................................130
  3.2.3 Practical Gage for Experimental Evaluation of Tool Geometry...132
3.3   Tool Cutting Edge Angles .....................................................................132
3.3.1  General Consideration................................................................132
: Z7 A( V! g# i$ p  3.3.2   Uncut ChipT in Non-free Cutting ..............................................134
  3.3.3   Influence on the Surface Finish..................................................142
: V$ K: j9 q+ o2 [8 ] 3.3.4  Tools with κr > 90°.....................................................................144
5 F& a% j' u/ P6 ]  3.3.5   Tool Minor Cutting Edge Angle ................................................147
) d8 H5 l/ a" i" Z3.4.  Edge Preparation ...................................................................................161
! P$ z' {5 y% r 3.4.1  General .......................................................................................161
1 N% {" E7 L5 a3 f  3.4.2   Shape and Extent........................................................................163
6 E3 W& ?2 ?' U7 s* F# g8 v% h 3.4.3  Limitations .................................................................................163
  3.4.4   What Edge Preparation Actually Does.......................................169
1 X: X6 r7 o$ w& m; o: K3.5   Rake Angle............................................................................................171
2 g9 Z" V8 F/ c- \  ~ 3.5.1  Introduction................................................................................171
  3.5.2   Influence on Plastic Deformation and Generazliations ..............175
% y0 J. Z  A& y/ ]6 x5 @  3.5.3   Effective Rake Angle .................................................................183
+ m/ z. H$ c8 V1 E  3.5.4   Conditions for Using High Rake Angles....................................189
3.6   Flank Angle ...........................................................................................191
" s. o3 x& I0 e1 ~! P) y* M4 r1 f3.7   Inclination Angle...................................................................................193
      3.7.1   Turning with Rotary Tools.........................................................195
3.7.2  Helical Treading Taps and Broaches..........................................197
4 E# D" z. t0 B; ?, e 3.7.3  Milling Tools..............................................................................198
: g6 i. C- Q' s6 [! SReferences......................................................................................................201
7 ~' D  S( z0 Z" i5 L4   Straight Flute and Twist Drills ...................................................................205
4.1   Introduction ...........................................................................................205
1 O$ d8 F8 x& d/ l4.2   Classification.........................................................................................206
4.3   Basic Terms...........................................................................................208
3 r- B1 a5 D7 c2 K$ e+ V$ ?5 t4.4   System Approach ..................................................................................211
4.4.1  System Objective .......................................................................212
( x- R# ~- n& X7 w% K. I9 T; g9 i 4.4.2  Understanding the Drilling System............................................212
  4.4.3.  Understanding the Tool..............................................................212
4.5.  Force System Constrains on the Drill Penetration Rate ........................213
  4.5.1   Force-balance Problem in Conventional Drills ..........................213
  4.5.2   Constrains on the Drill Penetration Rate....................................218
4.5.3  Drilling Torque ..........................................................................219
& z8 z+ c! r4 I( q& v) k- s 4.5.4  Axial Force.................................................................................220
  4.5.5   Axial Force (Thrust)-torque Coupling .......................................221
4.6   Drill Point ..............................................................................................223
2 m$ w6 [% A- T 4.6.1  Basic Classifications ..................................................................223
, d$ |# a3 Y6 V9 S$ w7 M  4.6.2   Tool Geometry Measures to Increase the Allowable  
Penetration Rate ....................................................................................224
, h4 X1 P% d5 k4 t( O4.7   Common Design and Manufacturing Flaws..........................................259
" A0 h  O9 l# j: q6 q8 J8 \6 t  4.7.1   Web Eccentricity/ Lip Index Error.............................................260
  4.7.2   Poor Surface Finish and Improper Tool Material/Hardness.......261
. t1 C- o1 M- P$ j' T1 D/ M, @  n 4.7.3  Coolant Hole Location and Size.................................................263
: x2 b* j: V- E/ l1 ~. h4.8   Tool Geometry ......................................................................................267
4 f/ z  m; B: H1 z$ h* [+ }- g8 M  4.8.1   Straight-flute and Twist Drills Particularities............................269
0 j4 K0 ?- z+ Y! `* j2 e# J  4.8.2   Geometry of the Typical Drill Point ..........................................270
  |5 a. m: ?+ K, n/ F7 g8 u  4.8.3   Rake Angle.................................................................................272
6 z4 ]0 k  g, I! g, _  4.8.4  Inclination Angle .........................................................................280
4.8.5  Flank Angle................................................................................281
  f. s$ m7 w' G) U* V  4.8.6   Geometry of a Cutting Edge Located at an Angle  
9 @' m* \' A% U   to the y0-plane ............................................................................292
/ N; N9 G- _/ Z8 V) p: N" H 4.8.7  Chisel Edge ................................................................................295
4 j8 f* R' ^; j7 Y1 w  4.8.8   Drill Flank is Formed by Two Planes: Generalization...............306
  4.8.9   Drill Flank Angle Formed by Three Planes ...............................310
4.8.10  Flank Formed by Quadratic Surfaces.........................................313
4.9   Load Over the Drill Cutting Edge .........................................................324
& R6 N6 h# U  [! C! m' H   4.9.1   Uncut Chip Thickness in Drilling ..............................................325
  4.9.2   Load Distribution Over the Cutting Edge ..................................327
4.10  Drills with Curved and Segmented Cutting Edges ................................328
2 [# D: ~8 {4 z1 V* q  4.10.1 Load of the Cutting Part of a Drill with Curved Cutting Edges .329
  4.10.2 Rake Angle.................................................................................332
& m# K+ H  e: C7 c. w& X3 uReferences......................................................................................................337
3 }2 W5 [9 |* a5   Deep-hole Tools............................................................................................341
' c/ \) ~8 B9 a$ ^0 G5.1   Introduction ...........................................................................................341
5.2   Generic Classification of Deep-hole Machining Operations.................343
7 S! I3 I- N2 z, j5.3   What Does ‘Self-piloting Tool’ Mean? .................................................345
9 O  s+ B5 l& n5 v  p  5.3.1   Force Balance in Self-piloting Tools..........................................345
+ X( e8 E. O  V5.4   Three Basic Kinematic Schemes of Drilling .........................................350
  5.4.1   Gundrill Rotates and the Workpiece is Stationary .....................351
3 w1 S+ P  c* ]; d% j 5.4.2  Workpiece Rotates and the Gundrill is Stationary .....................352
5.4.3  Counterrotation ..........................................................................352
  l$ R6 k  \: R- u9 s; `1 G1 n5.5   System Approach ..................................................................................353
7 ~: J9 s# S; ^) E$ V  5.5.1   Handling Tool Failure ................................................................353
0 X  ^# r1 I( Q 5.5.2  System Considerations ...............................................................354
5.6   Gundrills................................................................................................362
5.6.1  Basic Geometry..........................................................................362
5.6.2  Rake Surface ..............................................................................365
  5.6.3   Geometry of Major Flanks .........................................................370
5.6.4  System Considerations in Gundrill Design ................................390
2 q7 F) X* B6 Z( o0 d5.6.5   Examplification of Significance of the High MWF Pressure
  in the Bottom Clearance Space ..................................................423
  5.6.6   Example of Experimental Study ................................................425
/ ^2 v8 l3 }7 s  5.6.7   Optimization of Tool Geometry.................................................439
References......................................................................................................440
Appendix A  
, ]# E  {  o: T. ]! @* s, U+ BBasic Kinematics of Turning and Drilling.......................................................443
" @! D. A% g  ^6 J) r" y, s6 dA.1   Introduction ...........................................................................................443
$ f& P2 |7 Y8 F9 F' O8 M/ [A.2  Turning and Boring ...............................................................................444
  A.2.1  Basic Motions in Turning...........................................................444
2 \: f8 N# d' J& M! o6 \+ m+ |% o) n  A.2.2  Cutting Speed in Turning and Boring ........................................448
% I  K) b' ^; E8 p' K9 n+ c! I+ |  A.2.3  Feed and Feed Rate ....................................................................448
4 h1 R: [8 h3 L+ _$ b1 \  A.2.4  Depth of Cut...............................................................................449
A.2.5  Material Removal Rate ..............................................................449
! K+ T+ [% l2 q* n, p A.2.6  Resultant Motion........................................................................450
A.3  Drilling and Reaming ............................................................................450
& _- M- G+ U3 d$ u$ E% R+ y$ _ A.3.1  Basic Motions in Drilling...........................................................450
. O! E5 T: V% [6 ~! L A.3.2  Machining Regime.....................................................................451
( A" Q% s& x: S* O5 u, ]1 p) VA.4  Cutting Force and Power .......................................................................453
( N2 I2 ^  l- W3 b' j  A.4.1  Force System in Metal Cutting...................................................453
4 b- x$ S8 Y! w* t" C  A.4.2  Cutting Power ............................................................................454
2 F% g  b7 r3 }1 |8 Y6 R A.4.3  Practical Assessment of the Cutting Force.................................455
% U! b! h, F1 c" n, i8 l$ K1 gReferences......................................................................................................461
Appendix B  
/ V" P' K# V& T/ ~1 xANSI and ISO Turning Indexable Inserts and Holders.................................463
B.1   Indexable Inserts ...................................................................................463
! U- ^  U) c, R, ~# s  B.1.1  ANSI Code .................................................................................464
# z; f8 w* `* a4 F B.1.2  ISO Code....................................................................................471
* H( O, P1 p/ g  B.2 Tool Holders for Indexable Inserts (Single Point Tools) ......................491
  B.2.1   Symbol for the Method of Holding Horizontally Mounted  
Insert – Reference Position (1) ..............................................................492
  B.2.2   Symbol for Insert Shape – Reference Position (2) .....................493
  B.2.3   Symbol for Tool Style – Reference Position (3) ........................493
# B5 H" K9 s4 I: j  ?7 G  B.2.4   Letter Symbol Identifying Insert Normal Clearance –  
   Reference Position (4)................................................................494
( q8 ?6 c5 Y* X# d- P9 ?+ l. o  B.2.5   Symbol for Tool Hand – Reference position (5) ........................494
% j  g) G- F2 L  B.2.6  Symbol for Tool Height (Shank Height of Tool Holders  
    and Height of Cutting Edge) - Reference Position (6) ...............494
  B.2.7  Number Symbol Identifying Tool Holder Shank Width –  
   Reference Position (7)................................................................495
  B.2.8  Number Symbol Identifying Tool Length –  
) [6 F) d9 ^# D% C% f! Q   Reference Position (8)................................................................495
  B.2.9   Letter Symbol Identifying Indexable Insert Size –  
   Reference Position (9)................................................................497
, O" e3 C6 O% ]& A. @Appendix C  
* @3 y8 d' T/ b4 tBasics of Vector Analysis ..................................................................................499
C.1   Vectors and Scalars ...............................................................................499
C.2   Definition and Representation...............................................................500
C.2.1  Definitions..................................................................................500
6 t- q9 K& s) ]3 K0 f C.2.2  Basic Vector Operations ............................................................503
C.3   Application Conveniences.....................................................................509
C.4  Rotation: Linear and Angular Velocities...............................................511
  C.4.1   Planar Linear and Angular Velocities ........................................511
  C.4.2   Rotation: The Angular Velocity Vector .....................................515
3 {# a( o) X  i' r! L& bReferences ...........................................................................................................518
Appendix D  
5 a' Y6 X& [% J. F' ^% }Hydraulic Losses: Basics and Gundrill Specifics............................................519
D.1  Hydraulic Pressure Losses – General ....................................................519
D.1.1  Major Losses: Friction Factor ....................................................520
  D.1.2  Minor Losses (Losses Due to Form Resistance) ........................521
D.2  Concept of the Critical MWF Velocity and Flow Rate .........................521
8 n. }$ [) Y4 {5 j& m* I  D.2.1  MWF Flow Rate Needed for Reliable Chip Transportation.......522
) X2 G+ i2 {& }2 o% v( U' I  D.2.3  Example D.1...............................................................................527
! k6 f; m/ f, ED.3   Inlet MWF pressure...............................................................................528
D.4  Analysis of Hydraulic Resistances ........................................................532
  D.4.1  Analysis of Hydraulic Resistances Over Which the Designer  
! b& O/ o" e( M1 S6 k5 s    Has No or Little Control ............................................................532
  D.4.2  Variable Resistances Over Which the Designer Has Control ....535
& L8 U( m4 K4 w+ \D.5   Practical Implementation in the Drill Design ........................................539
References ..........................................................................................................543
Appendix E
0 z8 w+ |: K$ D7 y! V5 e8 K( tRequirements and Examples of Cutting Tool Drawings................................545
E.1   Introduction ...........................................................................................545
E.2   Tool Drawings – the Existent Practice ..................................................546
E.3   Tool Drawing Requrements ..................................................................548
9 P! r/ c  p# R1 Z- @# {  cE.4   Examples of Tool Drawing ...................................................................553
References ..........................................................................................................559
2 C  L" y) k5 hIndex…………………………………………………………………………….561


4 I, v$ d' W$ F/ U% X

李东ld

都是些神马？

showmark

埋头挖矿中。。。。。。。。。

lpg1988

好东西啊。。。只是，刀具不是我的工作。。。顶起，不沉。。。

机器鼠

专业人士自有看法。

招魂者

好东西啊，英文的，看着太费劲了

招魂者

从网上查找这本书是Springer Series in Advanced Manufacturing丛书中的一本
. {2 d0 }5 T" ]请问这套丛书共包含哪几本书