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Machining Tribology

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Machining Dynamics

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Abstract

Chapter 8 investigates the role of tribology, or the study of friction, wear, and lubrication, in machining performance. It is shown that tribology information is required to select machining parameters that minimize cost, including: (1) relationships between machining parameters, workpiece material properties, cutting forces, and the corresponding temperature field; (2) tool life, common wear features, and the dependence of machining cost on tool life; and (3) cutting fluids and their effect on tool life.

There are two important things for full success in life: 1. Don’t tell everything you know.

—Albert Einstein

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Notes

  1. 1.

    T. Schmitz recognizes the contributions of J. Karandikar to this experimental study.

  2. 2.

    T. Schmitz recognizes the contributions of H.S. Kim to this case study.

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Author information

Authors and Affiliations

  1. Department of Mechanical Engineering and Engineering Science, University of North Carolina at Charlotte, Charlotte, NC, USA

    Tony L. Schmitz & K. Scott Smith

Authors
  1. Tony L. Schmitz
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  2. K. Scott Smith
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Exercises

Exercises

  1. 1.

    Tribology is the study of _______________.

  2. 2.

    Consider orthogonal cutting of 304 stainless steel with the following parameters: hm = 0.1 mm, b = 4 mm, v = 2 m/s, α = 12 deg, ϕs = 26 deg, kt = 3200 N/mm2, and kn = 1200 N/mm2. Calculate the following parameters.

    • Ks (N/mm2)

    • β (deg)

    • L (mm)

    • hd (mm)

    • r

    • vc (m/s)

    • vs (m/s)

    • F (N)

    • Fs (N)

    • Ff (N)

    • Ps (W)

    • Pf (W)

  3. 3.

    An increase in cutting speed tends to increase the chip temperature. T/F

  4. 4.

    Built-up edge can cause the effective rake angle to change during a cutting operation. T/F

  5. 5.

    Consider the Taylor-type tool life model: C = vpfrqT, where C, p, and q are constants. Tests were performed and the tool life was measured; the data is provided in Table 8.6. Using this data determine the constants for the tool life model.

    Table 8.6 Tool life testing data
    Full size table
  6. 6.

    Using the populated tool life model from problem 5, plot the cutting speed (horizontal axis) versus the tool life on a log-log scale for feed values of 0.1 mm and 0.2 mm. Use a cutting speed range of 50 m/min to 300 m/min for the horizontal axis and a tool life range of 2 min to 4000 min on the vertical axis.

  7. 7.

    Using the data from Table 8.6 , determine the optimum cutting speed (m/min) by applying Eq. 8.31. For your calculation, use the cost parameters from Table 8.3 and a maximum permissible feed of 0.2 mm.

  8. 8.

    Calculate the mean power (kW) consumed in the following milling operation: Aluminum alloy workpiece with a specific cutting force of 710 N/mm2, slotting, 19.1 mm diameter endmill with four teeth, 8000 rpm, 3 mm axial depth, and 0.15 mm feed per tooth.

  9. 9.

    Define the acronym MQL.

  10. 10.

    Tool life is not affected by the machining stability. T/F

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Schmitz, T.L., Smith, K.S. (2019). Machining Tribology. In: Machining Dynamics. Springer, Cham. https://doi.org/10.1007/978-3-319-93707-6_8

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  • DOI: https://doi.org/10.1007/978-3-319-93707-6_8

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