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The whisker-like grain structures of SiN3 (Figure 216) [22] when added to Al2O3 give the tool toughness, excellent hot hardness and thermal shock resistance Some experts say that silicon nitride will take over where alumina-based ceramic tools have failed a quantum jump in performance Simply stated, tests have shown that silicon nitride materials handle applications such as high-speed roughing even milling of cast iron and nickel-based alloys at higher cutting speeds and chip load conditions than either hot-pressed ceramics or ceramic-coated carbides Some experts say that silicon nitride ceramics exhibit characteristics that combine the high-speed capability of traditional hotpressed ceramics with the impact resistance and high feed capability associated with carbides Silicon nitride tools are also effective when coated with aluminium oxide In one application, a grey cast iron automotive brake disc (180 HB) is rough faced In the past, simple aluminium oxide ceramics were used at cutting speeds of 1200 2000 sfm (366 610 m/min) The tool life was about 150 pieces per cutting edge, but tool breakage was a problem By switching to Grade SP4 aluminium-oxide-coated silicon nitride, supplied by NTK Cutting Tools, it was possible to increase the feed rate to 0020 ipr (0051 mm/rev) and still provide an average tool life of 400 pieces per cutting edge [21] The SiAlONs were developed as a more Fig 216: The microstructure of a silicon nitride economic alternative to hot-pressed silicon nitride ceramic [22] SiAlONs have a complex chemistry and are thought to be a family of alloys with a wide range of properties They are formed when silicon nitride (Si3N4), aluminium oxide (Al2O3) and aluminium nitride (AlN) are reacted together The hot hardness, fracture toughness and thermal shock resistance of fully dense SiAlON make it well suited for use in cutting tools The material is an attractive low cost alternative to hot-pressed silicon nitride for machining grey cast iron for automotive applications The material gives both an increased metal removal rate and a longer tool life compared with conventional cutting tools Tools using SiAlONs have also replaced cemented carbide tools for machining nickel-based super alloys These alloys are used for their heat resistance or in aerospace.



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Preface Acknowledgements 1 Precision Engineering 11 12 13 14 15 16 Introduction to Precision Engineering The Difference between Accuracy and Precision The Need for having a High Precision Developmental Perspective of Machining Precision Four Classes of Achievable Machining Accuracy Normal Machining 161 Gear Manufacture by Normal Machining 17 Precision Machining 171 Machining of Integrated Circuit Chips on a CNC Milling Machine for Failure Analysis 172 Precision Manufacture of Spherical and Aspheric Surfaces on Plastics and Glass 18 High-precision Machining 19 Ultra-precision Machining 191 Ultra-precision Processes and Nanotechnology 110 Thermal Considerations in Precision Engineering 111 References 112 Review Questions

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Contents 33 33 36 36 37 41 41 43 45 47 48 49 49 50 56 56 58 59 60 65 67 73 75 77 79 80 80 81 82 85 86 86 90 91 93 94





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2 Tool Materials for Precision Machining 21 Introduction 22 Coated Carbides 221 Laminated Carbides 222 CVD Coated Carbides 223 Coating of the First Generation of TiC (Cermets) 224 Coating of the Second Generation of TiC (Cermets) 225 PVD Coated Carbides 23 Ceramics 231 Hot-pressed Ceramics 232 Silicon Nitride Ceramics 233 Whisker Reinforced Ceramics 24 Diamonds 241 Crystallographic Planes 242 Natural Diamond 243 Synthetic Diamonds 244 Polycrystalline Diamond (PCD) 245 Single-crystal Diamond (SPSCD) 246 Diamond Coated Tools 247 Design of Diamond Tools 25 Cubic Boron Nitride (CBN) 251 Coated CBN 26 Tool and Work Material Compatibility 27 References 28 Review Questions 3 Mechanics of Materials Cutting 31 Introduction 32 An Overview of the Turning Operation and Tool Signature 321 Single-point Cutting Tools 33 Mechanics of Conventional Metal Cutting 331 Pure Orthogonal, Semi-orthogonal, Orthogonal and Oblique Cutting 332 Chip Formation and Cutting Forces in Metal Cutting 333 Merchant s Theory 334 Merchant s Shear Angle 335 Merchant s Modified Shear Angle (Bridgman s Theory) 336 Merchant s Strain Equation

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1. The human operator makes all of the high-level decisions. They are the intelligence behind the curtain, while the robot gets to worry about the low-level re exive actions. For really lame systems, the operator may be in direct control of the motors. 2. A semi-autonomous robot is only partially under operator control. The operator makes the big decisions and then turns the robot loose to implement them. Many times, it is impossible to have direct control of the robot, so it needs onboard intelligence to control itself between commands. Even if you have mostly direct control, wireless communication can be disrupted so the robot still needs to behave reasonably until the connection can be reestablished.

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