Metal cutting and high speed machining (Kluwer Academic / Plenum Publishers)

500 Pages·2016·24.53 MB·English

METAL CUTTING AND
HIGH SPEED MACHINING
Edited by
D. Dudzinski
Universite de Metz
Metz, France
A. Molinari
Universite de Metz
Enim
Metz, France
and
H. Schulz
Technical University of Darmstadt
Darmstadt, Germany
Kluwer Academic I Plenum Publishers
New York, Boston, Dordrecht, London, Moscow
Library of Congress Cataloging-in-Publication Data
Metal cutting and high speed machining/edited by D. Dudzinski, A. Molinari, and H. Schulz.
p. cm.
Papers presented at the Third International Conference on Metal Cutting and High
Speed Machining, June 2001, Metz, France.
Includes bibliographical references and index.
ISBN 0-306-46725-9
I. Metal-cutting tools-Congresses. 2. Metal-work-Congresses. 3. High-speed
machining-Congresses. I. Dudzinski, D., 1952- II. Molinari, A., 1948- Ill. Schulz,
Herbert, 1936- IV. International Conference on Metal Cutting and High Speed
Machining (3rd: 2001: Metz, France)
TJll86 .M378 2002
671.5'3-dc21
2001057982
Proceedings of the Third International Conference on Metal Cutting and High Speed Machining, held June
27-29, 2001, in Metz, France
ISBN 0-306-46725-9
©2002 Kluwer Academic I Plenum Publishers, New York
233 Spring Street, New York, New York 10013
http://www.wkap.nl/
1098765432
A C.l.P. record for this book is available from the Library of Congress
All rights reserved
No part of this book may be reproduced, stored in a retrieval system, or transmitted in any form or by any
means, electronic, mechanical, photocopying, microfilming, recording, or otherwise, without written
permission from the Publisher
Printed in the United States of America
PREFACE
This book gives a coherent overview of recent developments in Metal Cutting and High
Speed Machining, presenting the latest research of international groups in theoretical and
experimental approaches in this field. Topics covered include: mechanics of cutting,
numerical models, chatter vibrations, machining processes (drilling, high speed milling,
grinding, hard turning), cutting tools and coatings, dry cutting, computer aided
manufacturing, numerical control and command, process monitoring and adaptive control,
machine tool (in particular the Parallel Kinematic Machines) and components (spindles and
linear motor feed drive). Special attention is made to industrial applications, to aeronautical
materials, for example. Various facets of metal cutting are developed to stimulate
interdisciplinary approach.
The book is constituted by a selection of papers presented at the Third International
Conference on Metal Cutting and High Speed Machining which was held in Metz, France, on
June 27-29, 2001. This conference brought together 360 scientists, researchers and engineers
from 31 countries; it promoted fertile discussions and exchange of ideas. The Conference is
co-organized by the Universite de Metz, Ecole Nationale d'Ingenieurs de Metz and the
Darmstadt Technische Universitat with a two years interval.
Progress in metal cutting needs a synergy between many disciplines among which
mechanics, of course, for the analysis and the design of the whole process, but in combination
with material science and physico-chemistry for elaborating new tools, coatings and new
work materials, tribology for the modelling of dynamic friction at the tool-chip interface,
computing for the development of efficient software simulating and optimizing the cutting
processes, applied mathematics for process monitoring and control. Interactions between
these disciplines are illustrated in this book.
The editors would like to express their appreciation to all the authors for their
contributions to this book. Special thanks are due to the members of the scientific committee
of the conference.
It is hoped that this book will provide to manufacturing engineers, researchers, and
students, information, help and a necessary interdisciplinary view to solve problems
encountered in machining processes and to-propose new ideas and applications in this field.
D. Dudzinski, A. Molinari and H. Schulz
v
CONTENTS
MECHANICS OF CUTTING
I. ON THE SIMULATION OF MACHINING AT THE A TOM JC SCALE .........
R. Komanduri and M.L. Raff
2. DYNAMICS IN HIGH SPEED MACHINING.................................................. 21
G. Warnecke and S. Siems
3. INFLUENCE OF MATERIAL PROPERTIES ON SURFACE INTEGRITY
AND CHIP FORMATION IN HIGH SPEED TURNING....................... 31
E. Brinksmeier, P. Mayr, T. Lubben, P. Pouteau, and P. Diersen
4. DETERMINATION OF FORCES IN HIGH SPEED MACHINING (HSM)
FROM MACHINING TESTS AND AV ARIABLE FLOW STRESS
MACHINING THEORY.......................................................................... 41
B. Kristyanto, P. Mathew, and J. A. Arsecularatne
5. THERMOMECHANICAL MODELLING OF CUTTING AND
EXPERIMENT AL VALIDATION.......................................................... 51
A. Moufki, A. Devillez, D. Dudzinski, and A. Molinari
6. INFLUENCE OF HEAT TREATMENT AND CUTTING PARAMETERS
ON CHIP FORMATION AND CUTTING FORCES.............................. 69
H. Schulz and A. Sahm
7. MEASUREMENT AND SIMULATION OF TEMPERATURE AND
STRAIN FIELDS IN ORTHOGONAL METAL CUTTING................... 79
Y.K. Potdar and A.T. Zehnder
NUMERICAL APPROACH OF CUTTING AND MACHINING
8. A PARAMETRIC STUDY OF THE EFFECTS OF CUTTING
PARAMETERS ON CHIP FORMATION PROCESS ............................ 91
M.R. Movahhedy, M.S. Gadala, and Y. Altintas
vii
viii CONTENTS
9. THREE-DIMENSIONAL FINITE-ELEMENT ANALYSIS
OF HIGH-SPEED MACHINING............................................................. 107
J.F. Molinari
IO. PREDICTION OF CHIP MORPHOLOGY IN ORTHOGONAL
CUTTING BY MEANS OF A CUSTOMIZED
FINITE ELEMENT CODE....................................................................... 119
E. Ceretti, L. Filice, and F. Micari
CHATTER VIBRATIONS
11. KTNEMATICS AND DYNAMICS OF MILLING WITH ROUGHING
END MILLS .............................................................................................. 129
M.L. Campomanes
12. STUDY ON CHATTER VIBRATION IN RAMPING OF
SCULPTURED SURFACES.................................................................... 141
B.W. Ikua, H. Tanaka, F. Obata, and S. Sakamoto
13. REGENERATIVE STABILITY ANALYSIS OF HIGHLY
INTERRUPTED MACHINTNG ............................................................... 151
M.A. Davies, J.R. Pratt, B. Dutterer, and T.J. Bums
14. DETECTING CHATTER IN GRINDING ........ .. .. ........... .. ......... .. .. .. .. .... .... .. .. . 161
J. Gradisek, E. Govekar, I. Grabec, A. Baus, and F. Klocke
MACHINING PROCESSES
15. TOOL WEAR AND WORKPIECE SURFACE INTEGRITY WHEN
HIGH SPEED BALL NOSE END MILLING HARDENED AISI
Hl3............................................................................................................ 171
D.A. Axinte and R.C. Dewes
16. THE EFFECT OF CUTTING ENVIRONMENT AND TOOL COATTNG
WHEN HIGH SPEED BALL NOSE END MILLING TITANIUM
ALLOY..................................................................................................... 181
H. Niemann, E.G. Ng, H. Loftus, A. Sharman, R. Dewes, and D. Aspinwall
17. HIGH SPEED BALL NOSE END MILLING OF INCONEL 718 WITH
VARIABLE TOOL GEOMETRY- EXPERIMENTAL AND
FTNITE ELEMENT ANALYSIS.............................................................. 191
E.G. Ng, S.L. Soo, C. Sage, R. Dewes, and D. Aspinwall
CONTENTS ix
18. INFLUENCE OF MACHINING CONDITIONS ON RESIDUAL
STRESSES: SOME EXAMPLES ON AERONAUTIC
MATERIALS ...... .. .. .. ........... ......... ........ .. .. .. .... ........ ... .. .. .. ....... .. .. ..... .. ... .. . 20 I
L. Guerville and J. Vigneau
19. SURFACE INTEGRITY IN FINISH HARD TURNING OF GEARS............ 211
J. Rech, M. Lech, and J. Richon
20. WEAR TRENDS OF PCBN CUTTING TOOLS IN HARD TURNING ........ 221
T.G. Dawson and T.R. Kurfess
21. AN ANALYTICAL STUDY ON THE ST ABILITY OF DRILLING
AND REAMING...................................................................................... 233
J.A. Yang, V. Jaganathan, and R. Du
22. HIGH SPEED GRINDING: AN INDUSTRIAL STUDY OF
LUBRICATION PARAMETERS............................................................ 251
A. Devillez., 0. Sinot, P. Chevrier, and D. Dudzinski
23. USE OF A HIGH SPEED MACHINING CENTRE FOR THE CBN AND
DIAMOND GRINDING OF NICKEL-BASED SUPERALLOYS ......... 267
J. Burrows, R. Dewes, and D. Aspinwall
CUTTING TOOLS AND COATINGS, DRY CUTTING
24. SHEAR LOCALISATION AND ITS CONSEQUENCE ON TOOL
WEAR IN HIGH SPEED MACHINING................................................. 277
S.V. Subramanian, H.O. Gekonde, G. Zhu, and X. Zhang
25. HSC-CUTTING OF LIGHTWEIGHT ALLOYS WITH CVD-
DIAMOND COATED TOOLS................................................................ 289
F. Klocke, R. Fritsch, and J. Grams
26. ENHANCED WEAR RESISTANCE AND TOOL DURABILITY
USING MAGNETIZATION.................................................................... 301
M. El Mansori, K. Lafdi, and D. Paulmier
27. FUNCTIONALLY GRADED HARDMETAL SUBSTRATES FOR
COATED CUTTING TOOLS.................................................................. 311
J. Garcia, W. Lengauer, J. Vivas, K. Dreyer, H. van den Berg,
H.-W. Daub, and D. Kassel
28. INNER COOLING SYSTEMS-WEAR REDUCTION FOR DRY
CUTTING................................................................................................. 319
E. Uhlmann and T. Frost
x CONTENTS
29. MIST COOLANT APPLICATIONS IN HIGH SPEED MACHINING OF
ADVANCED MATERIALS..................................................................... 329
M. Dumitrescu, M.A. Elbestawi, and T.I. El-Wardany
CAD/CAM/NC
30. DEVELOPMENT OF CAM SYSTEM FOR HIGH SPEED MILLING.......... 341
K. Morishige, T. Sakamoto, Y. Takeuchi, I. Takahashi,
K. Kase, and M. Anzai
31. AB-CAM: AN AGENT-BASED METHODOLOGY FOR THE
MANUFACTURE OF STEP COMPLIANT FEATURE BASED
COMPONENTS........................................................................................ 351
R.D. Allen, R.S.U. Rosso, Jr., and S.T. Newman
32. ASSESSMENT OF THE DESCRIPTION FORMAT OF TOOL
TRAJECTORIES IN 3-AXIS HSM: OF SCULPTURED
SURFACES.............................................................................................. 363
E. Due, C. Lartigue, and S. Laporte
PROCESS MONITORING AND ADAPTIVE CONTROL
33. TOOL CONDITION MONITORING USING TRANSITION FUZZY
PROBABILITY........................................................................................ 375
R. Du, Y. Liu, Y. Xu, X. Li, Y.S. Wong, and G.S. Hong
34. TOOL WEAR MONITORING BY ON-LINE VIBRATION ANALYSIS
WITH WAVELET ALGORITHM........................................................... 393
G. Luo, D. Osypiw, and M. Irle
35. ADAPTIVE POWER FEEDBACK CONTROL IN CYLINDRICAL
TRAVERSE GRINDING ......................................................................... 407
K.A. Hekman, R.L. Hecker, and S.Y. Liang
MACHINE TOOL
36. A NEW MACHINE TOOL CONCEPT FOR ON SITE MAINTENANCE
OF LARGE METAL FORMING TOOLS: TRANSPORTABLE
MACHINING UNIT WITH HYBRID KINEMATIC STRUCTURE...... 417
H.K. TOnshoff, H.-C. Mohring, G. Gunther, E. Lubbers, and A. Schmidt
37. THE DESIGN OF PARALLEL KINEMATIC MACHINE TOOLS
USING KINET O STA TIC PERFORMANCE CRITERIA....................... 425
F. Majou, P. Wenger, and D. Chablat
CONTENTS xi
38. PARALLEL KINEMATIC MACHINES-DEVELOPMENT,
SOFTWARE METHODS AND EXPERIENCES.................................... 435
V. Maier
MACHINE TOOL COMPONENTS
39. HIGH VOLUME CUTTING OF ALUMINIUM.............................................. 445
H.Voll
40. EXPERIMENT AL STUDIES OF HIGH SPEED THERMO
MECHANICAL-DYNAMIC BEHAVIORS OF MOTORIZED
MACHINE TOOL SPINDLES ................................................................ 455
C.-W. Lin, J.F. Tu, and J. Kamman
41. ADVANTAGES IN APPLICATION OF LINEAR MOTOR MACHINES
IN DIE AND MOULD MANUFACTURING ......................................... 465
E. Abele, H. Schulz, and B. Bork
42. ROBUST MOTION CONTROL FOR LINEAR MOTOR DRIVES............... 475
D. Tong, A. Elfizy, and M.A. Elbestawi
AUTHOR INDEX................................................................................................. 487
KEYWORDS INDEX........................................................................................... 489
ON THE SIMULATION OF MACHINING
AT THE ATOMIC SCALE
Ranga Komanduri 1 and Lionel M. Raff 2
ABSTRACT
Molecular dynamics (MD) simulation is an extremely powerful technique for
investigating atomistic phenomenon. Almost all physical phenomena when considered at the
fundamental level can be attributed, directly or indirectly, to the forces acting between the
atoms that constitute the material. Atomic or molecular dynamics (MD) simulations are
playing an increasingly important role in the fields of materials science, physics, chemistry,
tribology, and engineering. This is because there is really no alternate approach to MD
simulation capable of handling such broad ranging problems at the required level of details,
namely, atomistic level. MD simulations are providing new data and exciting insights into
ultraprecision machining that cannot be obtained readily in any other way - theory or
experiment. In this paper, the principles of MD simulation, relative advantages and current
limitations of this technique, and the application of MD simulations in addressing a wide
range of machining problems will be presented.
l. INTRODUCTION
For a long time, miniaturization of products was limited essentially to one industry,
namely, the watch industry. Various components of a watch were fabricated mainly by
mechanical methods using minilathes, minidrilling machines, minimilling machines, and
1 Reg~ts Professor, Mechanical and Aerospace Engineering, Oklahoma State University, Stillwater,
OK 74Q78, U.S. A, Phone: [phone], Fax: [phone], e-mail:[email protected]
2 Regents Professor, Chemist!)' Department, Oklahoma State University, Stillwater, OK 74078, U. S. A
Metal Cutting and High Speed Machining, edited by
D. Dudzinski et al., Kluwer Academic/Plenum Publishers, 2002 1