Cutting Tool back matter Part 4 pdf

continued Metal Working Fluid MWF trouble-shooting guide – problems, pos-sible causes and solutions.. continued Metal Working Fluid MWF trouble-shooting guide – problems, pos-sible cause

Appendix 14 (continued) Metal Working Fluid (MWF) trouble-shooting guide – problems,

pos-sible causes and solutions [Courtesy of Kuwait Petroleum International Lubricants]

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Appendix 14 (continued) Metal Working Fluid (MWF) trouble-shooting guide – problems,

pos-sible causes and solutions [Courtesy of Kuwait Petroleum International Lubricants]

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Appendix 14 (continued) Metal Working Fluid (MWF) trouble-shooting guide – problems,

pos-sible causes and solutions [Courtesy of Kuwait Petroleum International Lubricants]

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Appendix 15 Machine tool spindle analysis – trouble-shooting guide [Courtesy of Lion

Preci-sion]

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Appendix 15 (continued) Machine tool spindle analysis – trouble-shooting guide [Courtesy of

Lion Precision]

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Appendix 16a Typical polar plots – quick-find charts [Courtesy of Renishaw plc]

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Appendix 16b Typical polar plot and resultant diagnostic print-out [Courtesy of Renishaw plc]

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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 qualified craftsman 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 gaintoolmak-ing a Full Technological

Cer-tificate in Production Engineering In the mid-1970’s,

the author worked for an industrial consultancy unit

the: Materials Advisory Service, based at The

Univer-sity of Southampton, while studying for a

post-gradu-ate Certificpost-gradu-ate 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 The 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 The 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,

cated and advanced in any educational establishment

in the UK For many years, the author also acted as a consultant for an international cutting fluid 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 The 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 fields 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

Abbés principle 439

Abbott-Firestone curve 312

absolute machining test 274

absorption coefficient (Kρc) 103

accelerated cutting-tool wear test 272

accuracy 518

accurate and precise first-off machining 246

acid/alkaline test 407

acme thread 155

acoustic emissions (AE) 539

acoustic emission sensor (AE) 347

active-suppression of vibration 127

adaptive compensation system 453

adaptive control 535

adaptive control constraint (ACC) 321

adaptive control optimisation (ACO) 535

adaptive error compensation 453

adaptive remeshing technique 357

adjustable balancing ring 469

airy-point 437

allergic reaction 420

alternating flank 193

amortisation 110

amplitude parameter 312

analysis of variance (ANOVA) 282

anisotropic, or isotropic surface 307

ANOVA test 282

anti-foaming agent 396

apparent density 277

aqueous-based cutting fluid 395

arbor 256

arc evaporation 17

arithmetic average (AA) 133, 312

arithmetic mean roughness (Ra) 313 arithmetic progression 277

arithmetic roughness Ra parameter 133 artefact stereometry 486

artificial intelligence 531

AI and neural network integration 538 artificial neural networks (ANN) 539 asperities 315

astigmatism 528 asymmetric drill head 116 atomic

diffusion process 335 levels of resolution 516 radius 530

attribute sampling 264 attrition wear 77 autocollimation 453 axial force

component 82 axial force (F) 41, 101

B

B-spline 502, 504 back-lash 155 eliminator 155 back-taper 520 back rake angle (α) 299 back spot-facing 145 bacteria

count 417 level 417 bacteriological effect 416 test method 407 balanced

modular tooling 230 turning 291

balk-failure 115

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tool system 219

boring bar

deflection 131

selection 122

boring tool technology 117

brinelling 230

building-up the tool file 242

built-up edge (BUE) formation 335

bulk hardness 273

bursting-pressure 480

C

canned cycle 75, 277

carbon entrapment 488

care, handling, control and usage –

of cutting fluid 409

catastrophic, or tertiary wear 339

cemented carbide 8

cementite 488

centre line average (CLA) 312

ceramic and cermet 19

cermet 22, 23

coated 23

chamfer 36

chasing a thread 200

chatter 74, 117, 297

and chip formation 297

and vibration prediction 357

in machining operation 294

chemical composition test 273

chemically affected layer (CAL) 360

chemical vapour deposition (CVD) 14

chevron error 528

chilled cast iron surface 156

chilled compressed air 427

chilling-effect 522

chip-breaker

wear 79

chip-breaking

envelope 76

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ratio 56 chloroparaffin 418 christmas tree routine 172 circular interpolation 301 clamping force 509 classification

of cemented carbide tool grade 12

of tool wear type 334 clearance angle – reduction (γ) 299 CNC processing speed 449 coefficient

of elasticity 127

of friction 353

of thermal expansion 525 compatibility test 407 complex machining: of sculptured surface 496 composed radial and pendulum play 139 composite-filling– machine tool base 509 compressive chip thickness 56

computer-aided design (CAD) 223 computer-aided product development 398 computerised-tool management 264 computer numerical control (CNC) 51 conduction 101

conical error 528 consolidation 4 constant-pressure test 272 constant chip-load 537 constant surface speed 75, 280 continuous chip 56

with a built-up edge (BUE) 58 continuous improvement program 242 contour-tracking tool/workpiece measurement 252 convection and radiation 101

core-drilling 135 correction of hole abnormality 118 corrosion

inhibitor 396 protection 390, 416 coulomb 353

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