| Foreword | p. ix |
| Preface | p. xi |
| Acknowledgements | p. xv |
| Introduction: Historical and Economic Context | p. 1 |
| The Metal Cutting (or Machining) Process | p. 1 |
| A Short History of Machining | p. 2 |
| Machining and the Global Economy | p. 4 |
| Summary and Conclusion | p. 7 |
| References | p. 8 |
| Metal Cutting Operations and Terminology | p. 9 |
| Introduction | p. 9 |
| Turning | p. 9 |
| Boring Operations | p. 12 |
| Drilling | p. 13 |
| Facing | p. 14 |
| Forming and Parting Off | p. 14 |
| Milling | p. 14 |
| Shaping and Planing | p. 16 |
| Broaching | p. 18 |
| Conclusion | p. 19 |
| References | p. 19 |
| Bibliography (Also see Chapter 15) | p. 19 |
| The Essential Features of Metal Cutting | p. 21 |
| Introduction | p. 21 |
| The Chip | p. 23 |
| Techniques for Study of Chip Formation | p. 24 |
| Chip Shape | p. 25 |
| Chip Formation | p. 26 |
| The Chip/tool Interface | p. 29 |
| Chip Flow Under Conditions of Seizure | p. 40 |
| The Built-up Edge | p. 41 |
| Machined Surfaces | p. 47 |
| Summary and Conclusion | p. 47 |
| References | p. 55 |
| Forces and Stresses in Metal Cutting | p. 57 |
| Introduction | p. 57 |
| Stress on the Shear Plane | p. 58 |
| Forces in the Flow Zone | p. 60 |
| The Shear Plane and Minimum Energy Theory | p. 62 |
| Forces in Cutting Metals and Alloys | p. 74 |
| Stresses in the Tool | p. 79 |
| Stress Distribution | p. 80 |
| Conclusion | p. 95 |
| References | p. 95 |
| Heat in Metal Cutting | p. 97 |
| Introduction | p. 97 |
| Heat In the Primary Shear Zone | p. 98 |
| Heat at the Tool/work Interface | p. 102 |
| Heat Flow at the Tool Clearance Face | p. 112 |
| Heat in Areas of Sliding | p. 113 |
| Methods of Tool Temperature Measurement | p. 114 |
| Measured Temperature Distribution in Tools | p. 121 |
| Relationship of Tool Temperature to Speed | p. 126 |
| Relationship of Tool Temperature to Tool Design | p. 128 |
| Conclusion | p. 130 |
| References | p. 130 |
| Cutting Tool Materials I: High Speed Steels | p. 132 |
| Introduction and Short History | p. 132 |
| Carbon Steel Tools | p. 133 |
| High Speed Steels | p. 138 |
| Structure and Composition | p. 140 |
| Properties of High Speed Steels | p. 144 |
| Tool Life and Performance of High Speed Steel Tools | p. 149 |
| Tool-life Testing | p. 163 |
| Conditions of Use | p. 166 |
| Further Development | p. 167 |
| Conclusion | p. 173 |
| References | p. 173 |
| Cutting Tool Materials II: Cemented Carbides | p. 175 |
| Cemented Carbides: an Introduction | p. 175 |
| Structures and Properties | p. 176 |
| Tungsten Carbide-Cobalt Alloys (WC-Co) | p. 177 |
| Tool Life and Performance of Tungsten Carbide-Cobalt Tools | p. 186 |
| Tungsten-Titanium-Tantalum Carbide Bonded with Cobalt | p. 202 |
| Performance of (WC+TiC+TaC) -Co Tools | p. 205 |
| Perspective: "Straight" WC-Co Grades versus the "Steel-Cutting" Grades | p. 209 |
| Performance of "TiC Only" Based Tools | p. 210 |
| Performance of Laminated and Coated Tools | p. 211 |
| Practical Techniques of Using Cemented Carbides for Cutting | p. 215 |
| Conclusion on Carbide Tools | p. 224 |
| References | p. 225 |
| Cutting Tool Materials III: Ceramics, CBN Diamond | p. 227 |
| Introduction | p. 227 |
| Alumina (Ceramic) Tools | p. 227 |
| Alumina-Based Composites (Al[subscript 2]O[subscript 3] + TiC) | p. 229 |
| Sialon | p. 231 |
| Cubic Boron Nitride (CBN) | p. 236 |
| Diamond, Synthetic Diamond, and Diamond Coated Cutting Tools | p. 239 |
| General Survey of All Tool Materials | p. 245 |
| References | p. 249 |
| Machinability | p. 251 |
| Introduction | p. 251 |
| Magnesium | p. 252 |
| Aluminum and Aluminum Alloys | p. 254 |
| Copper, Brass and Other Copper Alloys | p. 258 |
| Commercially Pure Iron | p. 269 |
| Steels: Alloy Steels and Heat-Treatments | p. 269 |
| Free-Cutting Steels | p. 278 |
| Austenitic Stainless Steels | p. 290 |
| Cast Iron | p. 293 |
| Nickel and Nickel Alloys | p. 296 |
| Titanium and Titanium Alloys | p. 303 |
| Zirconium | p. 307 |
| Conclusions on Machinability | p. 307 |
| References | p. 309 |
| Coolants and Lubricants | p. 311 |
| Introduction | p. 311 |
| Coolants | p. 313 |
| Lubricants | p. 322 |
| Conclusions on Coolants and Lubricants | p. 334 |
| References | p. 337 |
| High Speed Machining | p. 339 |
| Introduction to High Speed Machining | p. 339 |
| Economics of High Speed Machining | p. 340 |
| Brief Historical Perspective | p. 341 |
| Material Properties at High Strain Rates | p. 343 |
| Influence of Increasing Speed on Chip Formation | p. 348 |
| Stainless Steel | p. 352 |
| AISI 4340 | p. 359 |
| Aerospace Aluminum and Titanium | p. 360 |
| Conclusions and Recommendations | p. 363 |
| References | p. 368 |
| Modeling of Metal Cutting | p. 371 |
| Introduction to Modeling | p. 371 |
| Empirical Models | p. 373 |
| Review of Analytical Models | p. 374 |
| Mechanistic Models | p. 375 |
| Finite Element Analysis Based Models | p. 382 |
| Artificial Intelligence Based Modeling | p. 397 |
| Conclusions | p. 404 |
| References | p. 406 |
| Management of Technology | p. 411 |
| Retrospective and Perspective | p. 411 |
| Conclusions on New Tool Materials | p. 412 |
| Conclusions on Machinability | p. 414 |
| Conclusions on Modeling | p. 416 |
| Machining and the Global Economy | p. 417 |
| References | p. 422 |
| Exercises For Students | p. 425 |
| Review Questions | p. 425 |
| Interactive Further Work on the Shear Plane | p. 434 |
| Bibliography and Selected Web-sites | p. 435 |
| Index | p. 439 |
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