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Machining Operations Are Conducted on Machine Tools Having a Rotating Spindle

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Machining Operations Are Conducted on Machine Tools Having a Rotating Spindle TABLE OF CONTENTS MACHNING OPERATIONS CUTTING SPEEDS AND FEEDS ESTIMATING SPEEDS AND MACHINING POWER 978 Cutting Tool Materials 982 Cutting Speeds 1044 Planer Cutting Speeds 983 Cutting Conditions 1044 Cutting Speed and Time 983 Selecting Cutting Conditions 1044 Planing Time 983 Tool Troubleshooting 1044 Speeds for Metal-Cutting Saws 985 Cutting Speed Formulas 1044 Turning Unusual Material 987 RPM for Various Cutting Speeds 1046 Estimating Machining Power and Diameter 1046 Power Constants SPEED AND FEED TABLES 1047 Feed Factors 1048 Tool Wear Factors 991 Introduction 1050 Metal Removal Rates 991 Feeds and Speeds Tables 1051 Estimating Drilling Thrust, 995 Speed and Feed Tables for Turning Torque, and Power 1000 Tool Steels 1053 Work Material Factor 1001 Stainless Steels 1053 Chisel Edge Factors 1002 Ferrous Cast Metals 1054 Feed Factors 1004 Turning-Speed Adjustment 1055 Drill Diameter Factors Factors MACHINING ECONOMETRICS 1004 Tool Life Factors 1005 Adjustment Factors for HSS 1056 Tool Wear And Tool Life Tools Relationships 1006 Copper Alloys 1056 Equivalent Chip Thickness (ECT) 1007 Titanium and Titanium Alloys 1057 Tool-life Relationships 1008 Superalloys 1061 The G- and H-curves 1009 Speed and Feed Tables for Milling 1062 Tool-life Envelope 1012 Slit Milling 1065 Forces and Tool-life 1013 Aluminium Alloys 1067 Surface Finish and Tool-life 1014 Plain Carbon and Alloy Steels 1069 Shape of Tool-life Relationships 1018 Tool Steels 1070 Minimum Cost 1019 Stainless Steels 1071 Production Rate 1021 Ferrous Cast Metals 1071 The Cost Function 1023 High Speed Steel Cutters 1072 Global Optimum 1025 Speed Adjustment Factors 1073 Economic Tool-life 1026 Radial Depth of Cut 1076 Machine Settings and Cost 1028 Tool Life Calculations 1029 Drilling, Reaming, and Threading 1076 Nomenclature 1030 Plain Carbon and Alloy Steels 1077 Cutting Formulas 1035 Tool Steels 1081 Variation Of Tooling And Total 1036 Stainless Steels Cost 1037 Ferrous Cast Metals 1082 Optimized Data 1039 Light Metals 1085 High-speed Machining 1040 Adjustment Factors for HSS Econometrics 1041 Copper Alloys 1086 Chip Geometry in Milling 1041 Tapping and Threading 1088 Chip Thickness 1043 Cutting Speed for Broaching 1090 Forces and Tool-life 1091 High-speed Milling 1092 Econometrics Comparison 974 TABLE OF CONTENTS SCREW MACHINE FEEDS AND GRINDING FEEDS AND SPEEDS SPEEDS 1120 Basic Rules 1094 Automatic Screw Machine Tools 1120 Wheel life T and Grinding Ratio 1094 Knurling 1121 ECT in Grinding 1094 Revolution for Knurling 1122 Optimum Grinding Data 1094 Cams for Threading 1124 Surface Finish, Ra 1095 Cutting Speeds and Feeds 1125 Spark-out Time 1097 Spindle Revolutions 1126 Grinding Cutting Forces 1098 Practical Points on Cam 1127 Grinding Data 1099 Stock for Screw Machine 1128 Grindability Groups Products 1128 Side Feed, Roughing and 1101 Band Saw Blade Selection Finishing 1102 Tooth Forms 1129 Relative Grindability 1102 Types of Blades 1130 Grindability Overview 1103 Band Saw Speed and Feed Rate 1130 Procedure to Determine Data 1104 Bimetal Band Saw Speeds 1136 Calibration of Recommendations 1105 Band Saw Blade Break-In 1138 Optimization CUTTING FLUIDS GRINDING AND OTHER ABRASIVE PROCESSES 1107 Types of Fluids 1107 Cutting Oils 1139 Grinding Wheels 1107 Water-Miscible Fluids 1139 Abrasive Materials 1108 Selection of Cutting Fluids 1140 Bond Properties 1109 Turning, Milling, Drilling and 1140 Structure Tapping 1141 ANSI Markings 1110 Machining 1141 Sequence of Markings 1111 Machining Magnesium 1142 ANSI Shapes and Sizes 1112 Metalworking Fluids 1142 Selection of Grinding Wheel 1112 Classes of Metalworking fluids 1143 Standard Shapes Ranges 1112 Occupational Exposures 1150 Grinding Wheel Faces 1113 Fluid Selection, Use, and 1151 Classification of Tool Steels Application 1152 Hardened Tool Steels 1114 Fluid Maintenance 1156 Constructional Steels 1115 Respiratory Protection for 1157 Cubic Boron Nitride Workers 1158 Dressing and Truing 1158 Tools and Methods for Dressing MACHINING NONFERROUS and Truing METALS 1160 Guidelines for Truing and 1116 Machining Dressing 1116 Aluminium 1161 Diamond Truing and Crossfeeds 1117 Magnesium 1161 Size Selection Guide 1118 Zinc Alloy Die-Castings 1162 Minimum Sizes for Single-Point 1118 Monel and Nickel Alloys Truing Diamonds 1119 Copper Alloys 1119 Hard Rubber 975 TABLE OF CONTENTS GRINDING AND OTHER GRINDING AND OTHER ABRASIVE PROCESSES (Cont.) ABRASIVE PROCESSES (Cont.) 1163 Diamond Wheels 1183 Centerless Grinding 1163 Shapes 1184 Through-feed Method of Grinding 1164 Core Shapes and Designations 1184 In-feed Method 1164 Cross-sections and Designations 1184 End-feed Method 1165 Designations for Location 1184 Automatic Centerless Method 1166 Composition 1184 Centerless Grinding 1167 Designation Letters 1185 Surface Grinding 1168 Selection of Diamond Wheels 1186 Principal System 1168 Abrasive Specification 1186 Grinding Wheel 1169 Handling and Operation Recommendations 1169 Speeds and Feeds 1188 Principal Systems 1170 Grinding Wheel Safety 1189 Process Data for Surface Grinding 1170 Safety in Operating 1190 Basic Process Data 1170 Handling, Storage and Inspection 1190 Faults and Possible Causes 1170 Machine Conditions 1192 Offhand Grinding 1171 Grinding Wheel Mounting 1192 Floor- and Bench-Stand Grinding 1171 Safe Operating Speeds 1192 Portable Grinding 1172 Portable Grinders 1192 Swing-Frame Grinding 1175 Cylindrical Grinding 1193 Mounted Wheels and Mounted 1175 Plain, Universal, and Limited- Points Purpose Machines 1193 Abrasive Belt Grinding 1175 Traverse or Plunge Grinding 1193 Application of Abrasive Belts 1175 Work Holding on Machines 1193 Selection Contact Wheels 1176 Work-Holding Methods 1195 Abrasive Cutting 1176 Selection of Grinding Wheels 1196 Cutting-Off Difficulties 1177 Wheel Recommendations 1196 Honing Process 1177 Operational Data 1197 Rate of Stock Removal 1178 Basic Process Data 1197 Formula for Rotative Speeds 1178 High-Speed 1198 Factors in Rotative Speed 1179 Areas and Degrees of Automation Formulas 1179 Troubles and Their Correction 1198 Eliminating Undesirable Honing 1180 Chatter Conditions 1180 Spirals on Work 1199 Tolerances 1180 Marks on Work 1199 Laps and Lapping 1181 Burning and Discoloration of 1199 Material for Laps Work 1199 Laps for Flat Surfaces 1181 Thread on Work 1200 Grading Abrasives 1182 Inaccuracies in Work 1200 Charging Laps 1182 Inaccurate Work Sizing 1200 Rotary Diamond Lap 1182 Uneven Traverse or Infeed of 1201 Grading Diamond Dust Wheel Head 1201 Cutting Properties 1183 Wheel Defects 1201 Cutting Qualities 1183 Wheel Loading and Glazing 1202 Wear of Laps 1183 Wheel Breakage 1202 Lapping Abrasives 1202 Effect on Lapping Lubricants 1202 Lapping Pressures 1202 Wet and Dry Lapping 1203 Lapping Tests 976 TABLE OF CONTENTS ARBORS, CHUCKS, AND NUMERICAL CONTROL SPINDLES PROGRAMMING 1203 Portable Grinding Tools 1240 Programming 1203 Circular Saw Arbors 1243 Postprocessors 1203 Spindles for Geared Chucks 1243 G-Code Programming 1203 Spindle Sizes 1243 Format Classification 1204 Standard Shapes of Mounted 1243 Letter Addresses Wheels 1245 Sequence Number (N-Word) 1207 Straight Grinding Wheel Spindles 1245 Preparatory Word (G-Word) 1207 Threaded and Tapered Spindles 1249 Miscellaneous Functions 1208 Square Drives for Portable Air 1250 Feed Function (F-Word) 1209 Abrasion Tool Spindles 1251 Spindle Function (S-Word) 1210 Hexagonal Chucks for Portable 1251 Tool Function (T-Word) Air 1253 Linear Interpolation 1210 Hexagon Shanks for Portable Air 1254 Circular Interpolation 1255 Helical and Parabolic KNURLS AND KNURLING Interpolation 1211 Knurls and Knurling 1256 Subroutine 1211 ANSI Standard 1258 Conditional Expressions 1211 Preferred Sizes 1258 Fixed (Canned) Cycles 1211 Specifications 1262 Turning Cycles 1212 Cylindrical Tools 1262 Thread Cutting 1213 Flat Tools 1263 APT Programming 1213 Specifications for Flat Dies 1265 APT Computational Statements 1213 Formulas to Knurled Work 1265 APT Geometry Statements 1214 Tolerances 1266 Points, Lines and Circles 1215 Marking on Knurls and Dies 1270 APT Motion Statements 1215 Concave Knurls 1271 Contouring Cutter Movements 1272 Circles and Planes MACHINE TOOL ACCURACY 1274 3-D Geometry 1275 APT Postprocessor Statements 1219 Degrees of Accuracy Expected 1277 APT Example Program with NC Machine Tool 1279 APT for Turning 1220 Part Tolerances 1280 Indexable Insert Holders for NC NUMERICAL CONTROL 1281 Insert Radius Compensation 1284 Threading Tool Insert Radius 1225 Introduction 1284 V-Flange Tool Shanks 1225 CNC Technology 1286 Retention Knobs 1225 Numerical Control vs. Manual Operations CAD/CAM 1226 Numerical Control Standards 1287 CAD/CAM 1229 Programmable Controller 1289 Drawing Projections 1233 Closed-Loop System 1290 Drawing Tips and Traps 1233 Open-Loop System 1294 Sizes of Lettering on Drawing 1233 Adaptive Control 1294 Drawing Exchange Standards 1234 Flexible Manufacturing Systems 1296 Rapid Automated Prototyping 1235 Flexible Manufacturing Cell 1296 DNC 1235 Flexible Manufacturing Module 1297 Machinery Noise 1235 Axis Nomenclature 1297 Measuring Machinery Noise 1238 Total Indicator Reading 977 978 SPEEDS AND FEEDS CUTTING SPEEDS AND FEEDS Work Materials.—The large number of work materials that are commonly machined vary greatly in their basic structure and the ease with which they can be machined. Yet it is possible to group together certain materials having similar machining characteristics, for the purpose of recommending the cutting speed at which they can be cut. Most materials that are machined are metals and it has been found that the most important
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