Appendix 14. (continued) Metal Working Fluid (MWF) trouble-shooting guide – problems, pos- sible causes and solutions. [Courtesy of Kuwait Petroleum International Lubricants] . Appendix Appendix 14. (continued) Metal Working Fluid (MWF) trouble-shooting guide – problems, pos- sible causes and solutions. [Courtesy of Kuwait Petroleum International Lubricants] . Appendix Appendix 14. (continued) Metal Working Fluid (MWF) trouble-shooting guide – problems, pos- sible causes and solutions. [Courtesy of Kuwait Petroleum International Lubricants] . Appendix Appendix 15. Machine tool spindle analysis – trouble-shooting guide. [Courtesy of Lion Preci- sion] . Appendix Appendix 15. (continued) Machine tool spindle analysis – trouble-shooting guide. [Courtesy of Lion Precision] . Appendix Appendix 16a. Typical polar plots – quick-nd charts. [Courtesy of Renishaw plc]. Appendix Appendix 16b. Typical polar plot and resultant diagnostic print-out. [Courtesy of Renishaw plc]. Appendix Graham T. Smith, MPhil (Brunel), PhD (Birmingham), C Eng, FIMechE, FIEE (Formerly: Professor of Industrial Engineering, Southampton Solent University, UK) Graham T. Smith started his engineering career in the early 1960’s at a West Midlands company that manu- factured precision automotive parts by drop forging and pressing. He was trained in a large Die-shop in a heavy toolmaking environment, becoming a fully- skilled and qualied crasman. In the late 1960’s, he moved to the London area and joined initially, an aerospace company working as a prototype toolmaker, then later precision Jig-boring at an optical toolmak- ing company, while gaining a Full Technological Cer- ticate in Production Engineering. In the mid-1970’s, the author worked for an industrial consultancy unit the: Materials Advisory Service, based at e Univer- sity of Southampton, while studying for a post-gradu- ate Certicate of Advanced Study in Metallurgical Quality Control, which was then followed by a Master of Philosophy degree in Machinability – both at Bru- nel University. Later, while working as a lecturer in the Mechanical Engineering Department at e University of Birmingham, he completed a Doctor of Philosophy degree in Machined Surface Integrity. While working at the Southampton Solent Univer- sity – in the 1990’s, the author was instrumental in set- ting up a fully-industrialised Flexible Manufacturing System, featuring an integrated range of turning and machining centres, robotic handling and a CMM for part quality assessment. e tooling was of the mod- ular type and the machines equipped with adaptive control, with each machine tool being equipped with touch-trigger probing. At the time of its installation, About the Author this FMS plant was probably one of the most sophisti- cated and advanced in any educational establishment in the UK. For many years, the author also acted as a consultant for an international cutting uid producer and distributor – industrial ‘trouble-shooting’, as well as undertaking many complex machinability short- and long-term duration projects, for a range of indus- trial and aerospace companies. In the 1990’s the author was one of the three found- ing members of the international conference on: La- ser Metrology and Machine Performance, which has now ‘visited’ numerous university venues within the UK. Later, the author was both the originator and then Chairman of the international conference on Industrial Tooling, which until recently resided at Southampton, but now is hosted by Mississippi State University. e notable features of this conference was a large tooling- based exhibition – run by the conference secretary: Dr Guy Littlefair, plus a range of industrial-based tool- ing and machine tool speakers, with some exceptional pioneering researchers in the elds of: metal cutting; surface integrity and metrology. Typical of these ‘Key- note speakers’ which notably included such alumini as Professors: Milton C. Shaw; Ranga Komanduri; E. Brinksmeier; David J. Whitehouse; John T. Berry; plus Dr M. Eugene Merchant – to name but a few. Professor Smith has lectured widely within the UK and across both Europe and North America, while he continues to undertake industrial consultancy and Ex- pert Witness litigation activities. Subject Index 180° semi-circle entry cycle 206 90° quarter circle entry cycle 206 γ-solid solution’ 488 A Abbés principle 439 Abbott-Firestone curve 312 absolute machining test 274 absorption coecient (Kρc) 103 accelerated cutting-tool wear test 272 accuracy 518 accurate and precise rst-o machining 246 acid/alkaline test 407 acme thread 155 acoustic emissions (AE) 539 acoustic emission sensor (AE) 347 active-suppression of vibration 127 adaptive compensation system 453 adaptive control 535 adaptive control constraint (ACC) 321 adaptive control optimisation (ACO) 535 adaptive error compensation 453 adaptive remeshing technique 357 adjustable balancing ring 469 airy-point 437 allergic reaction 420 alternating ank 193 amortisation 110 amplitude parameter 312 analysis of variance (ANOVA) 282 anisotropic, or isotropic surface 307 ANOVA test 282 anti-foaming agent 396 apparent density 277 aqueous-based cutting uid 395 arbor 256 arc evaporation 17 arithmetic average (AA) 133, 312 arithmetic mean roughness (Ra) 313 arithmetic progression 277 arithmetic roughness Ra parameter 133 artefact stereometry 486 articial intelligence 531 AI and neural network integration 538 articial neural networks (ANN) 539 asperities 315 astigmatism 528 asymmetric drill head 116 atomic diusion process 335 levels of resolution 516 radius 530 attribute sampling 264 attrition wear 77 autocollimation 453 axial force component 82 axial force (F) 41, 101 B B-spline 502, 504 back-lash 155 eliminator 155 back-taper 520 back rake angle (α) 299 back spot-facing 145 bacteria count 417 level 417 bacteriological eect 416 test method 407 balanced modular tooling 230 turning 291 balk-failure 115 – – – – – – – – – – – – ball-nosed slot-drill 153 ball bearing spindle design 440 ballistic cutting speeds 432 beilby layer 362 bell-mouthing 135 eect 94 beta-function 324 bird nest 82 bird nesting 193 black, or mixed ceramic 22 block 450 processing time 449 tool system 219 boring bar deection 131 selection 122 boring tool technology 117 brinelling 230 building-up the tool le 242 built-up edge (BUE) formation 335 bulk hardness 273 bursting-pressure 480 C canned cycle 75, 277 carbon entrapment 488 care, handling, control and usage – of cutting uid 409 catastrophic, or tertiary wear 339 cemented carbide 8 cementite 488 centre line average (CLA) 312 ceramic and cermet 19 cermet 22, 23 coated 23 chamfer 36 chasing a thread 200 chatter 74, 117, 297 and chip formation 297 and vibration prediction 357 in machining operation 294 chemical composition test 273 chemically aected layer (CAL) 360 chemical vapour deposition (CVD) 14 chevron error 528 chilled cast iron surface 156 chilled compressed air 427 chilling-eect 522 chip-breaker wear 79 chip-breaking envelope 76 – – – – – – – – – – – technology 66 chip-development 54 chip-evacuation/-exhaust 157 chip-ow 77, 88 analysis 355 chip-gusset 155 chip-hammering 71 chip-pocket 155 chip-steaming 76 chip-thinning strategy 166 chip morphology 75 chip thickness 69 ratio 56 chloroparan 418 christmas tree routine 172 circular interpolation 301 clamping force 509 classication of cemented carbide tool grade 12 of tool wear type 334 clearance angle – reduction (γ) 299 CNC processing speed 449 coecient of elasticity 127 of friction 353 of thermal expansion 525 compatibility test 407 complex machining: of sculptured surface 496 composed radial and pendulum play 139 composite-lling– machine tool base 509 compressive chip thickness 56 computer-aided design (CAD) 223 computer-aided product development 398 computerised-tool management 264 computer numerical control (CNC) 51 conduction 101 conical error 528 consolidation 4 constant-pressure test 272 constant chip-load 537 constant surface speed 75, 280 continuous chip 56 with a built-up edge (BUE) 58 continuous improvement program 242 contour-tracking tool/workpiece measurement 252 convection and radiation 101 core-drilling 135 correction of hole abnormality 118 corrosion inhibitor 396 protection 390, 416 coulomb 353 – – – – – – – – – – – Subject Index . 44 0 ballistic cutting speeds 43 2 beilby layer 362 bell-mouthing 135 eect 94 beta-function 3 24 bird nest 82 bird nesting 193 black, or mixed ceramic 22 block 45 0 processing time 44 9 tool. 2 64 attrition wear 77 autocollimation 45 3 axial force component 82 axial force (F) 41 , 101 B B-spline 502, 5 04 back- lash 155 eliminator 155 back- taper 520 back rake angle (α) 299 back. 520 back rake angle (α) 299 back spot-facing 145 bacteria count 41 7 level 41 7 bacteriological eect 41 6 test method 40 7 balanced modular tooling 230 turning 291 balk-failure 115 – – – – – – – – – – – – ball-nosed