ABSTRACT
Machining by cutting produces accurate parts by removing the machining allowance in the form of chips by using cutting tools that are harder than the workpiece and will penetrate it. Depending on the accuracy requirements, hand tools, power-driven cutting tools, or common machine tools are used. Generally, the machining system consists of the cutting tool, the workpiece, and the machine tool. The machine tool is responsible for
• Application of the cutting power • Guiding or limiting the tool/workpiece movements • Controlling the cutting variables, such as the cutting speed, depth of
cut, feed rate, and lubrication • Providing the manufacturing facilities, the clamping of the tool, and
the workpiece
The choice of the proper cutting tool and machining variables depends upon the workpiece material properties, heat treatment, temperature, and the amount of work hardening prior to machining. Cutting tool material and geometry play a significant role in the characteristics of the machining process, wear resistance, cost, product accuracy, and surface quality of the machined parts (Figure 2.1). Performance indices of machining processes are determined by measurements of shear angle, cutting forces, power consumption, tool temperature and wear, and machine tool deflection and vibrations. The impact of such measurements on the machined part’s dimensional accuracy and surface quality is of major importance to manufacturing engineers.
