Machinability of Engineering Materials

1 The Concept of Machinability.- 1.1. Introduction.- 1.2. Definition of Machinability.- 2 Fundamental Aspects of the Machining Process.- 2.1. Mechanics of Metal Cutting.- 2.1.1. Chip formation.- 2.1.2. The effect of changes in cutting parameters on cutting forces.- 2.1.3. The effect of changes in cutting parameters on cutting temperatures.- 2.2. Tool Wear.- 2.2.1. Mechanisms of wear.- 2.2.2. Types of wear.- 2.2.3. Relationship between tool wear and time.- 2.2.4. Relationship between tool wear and cutting conditions.- 2.2.5. Relationship between tool life and temperature.- 2.2.6. Tool life criteria.- 2.3. Surface Finish.- 2.3.1. Introduction.- 2.3.2. Mechanism of surface finish production.- 2.3.3. Factors which influence surface finish production.- 2.4. Chip Formers.- 2.4.1. Mechanics of chip formers.- 2.4.2. Effect of cutting conditions on chip forming.- 2.4.3. Effect of chip formers on cutting forces.- 2.4.4. Effect of chip formers on tool wear.- 2.5. The Action of Cutting Fluids.- References.- 3 The Assessment of Machinability.- 3.1. Types of Machinability Test.- 3.2. Short Machinability Tests.- 3.3. Non-Machining Tests.- 3.3.1. Chemical composition tests.- 3.3.2. Microstructure tests.- 3.3.3. Physical properties tests.- 3.4. Machining Tests.- 3.4.1. The constant pressure test.- 3.4.2. The rapid facing test.- 3.4.3. Tapping tests.- 3.4.4. Degraded tool tests.- 3.4.5. Accelerated wear tests.- 3.4.6. High-speed-steel tool wear rate test.- 3.4.7. Taper turning test.- 3.4.8. Variable-rate machining test.- 3.4.9. Step turning test.- 3.5. Combination of Machining Parameters.- 3.6. Machinability Assessment for Processes Other than Single Point Turning.- 3.6.1. Introduction.- 3.6.2. Machinability assessment in drilling.- 3.6.3. Machinability assessment in milling.- 3.7. Machinability Assessment Relating One Process to Another.- 3.8. On-Line Assessment of Tool Wear.- References.- 4 Tool Materials.- 4.1. Historical Background.- 4.2. Requirements of Tool Materials.- 4.3. High-Speed Steels.- 4.3.1. Introduction.- 4.3.2. Structure of high-speed steels.- 4.3.3. Heat treatment of high-speed steels.- 4.3.4. Applications of high-speed steels.- 4.4. Cemented Carbides.- 4.4.1. Introduction.- 4.4.2. Classification of cemented carbides.- 4.4.3. Structure and properties of cemented carbides.- 4.4.4. Mixed cemented carbides bonded with cobalt.- 4.4.5. Coated cemented carbides.- 4.4.6. Titanium carbide cemented carbides.- 4.5. Cast Cobalt Alloys.- 4.6. Ceramic Cutting Tool Materials.- 4.7. Diamond.- References.- 5 Workpiece Materials.- 5.1. Introduction.- 5.2. Ferrous Materials.- 5.2.1. Carbon steels.- 5.2.2. Free-machining steels.- 5.2.3. Stainless steels.- 5.2.4. Cast irons.- 5.3. Titanium Alloys.- 5.4. Nickel-Based Alloys.- 5.5. Aluminium Alloys.- 5.6. Magnesium and its Alloys.- 5.7. Copper and its Alloys.- References.- 6 The ISO Machinability Test.- 6.1. Introduction.- 6.2. Reference Work pieces.- 6.3. Reference Tool Materials and Tool Geometries.- 6.4. Reference Cutting Fluids.- 6.5. Cutting Conditions.- 6.6. Tool Life Criteria and Tool Wear Measurements.- 6.7. Tool Wear Measurement.- 6.8. Equipment.- 6.9. Tool Life Test Procedure.- 6.10. Evaluation of Tool Life Data.- 7 The Effect of Machinability Data on Metal Removal Performance and Economics.- 7.1. Introduction.- 7.2. Criteria of Performance.- 7.3. Economics of Turning Operations.- 7.4. Machining for Minimum Cost.- 7.5. Machining for Maximum Production.- 7.6. Machining for Maximum Profit.- 7.7. Machinability Data Applied to Milling.- 7.8. Reliability of Machinability Data.- Reference.- Appendix 1 Analysis to Determine Cutting Temperatures in Single Point Metal Cutting.- Appendix 2 Analyses for Two Short Absolute Machinability Tests.- A2.1 The Variable-Rate Machining Test.- A2.2 The Step Turning Test.