counter-boring 142 trepanning 107 countersinks 142 couple unbalance 469 crack initiation 368 crater wear 334 creating a tool management and document database 240 creep 368 critical cooling velocity 488 cross-honing 313 cross-talk 345 cubic boron nitride (CBN) 25, 30, 507 cusp 64 customised drilling 110 customised milling cutter tooling 177 cut-o 308 cut-to-cut time 215 cutter location source le (CLSF) 505 cutting parameter – decision 123 cutting-unit system 216 cutting data 49 cutting edge chipping 337 cutting uid based health issue 420 classication 398 mist 422 quality control 404 testing 414 cutting force 201 dynamometry 343 cutting force (∆Fc) 105 cutting insert edge preparation 36 shape 105 cutting speed 200 cutting stiness (Ks) 297, 299 cutting time 341 cutting tool condition monitoring 531 cutting toolholder/insert selection 43 cycle-time 150 cylindricity 135, 492 D datum 110 deck of cards principle 53 deep-hole drilling 96, 113, 117 degraded tool test 272 degree of freedom 128 delay mark 206 – – – – – – – – – – – departure from roundness 135 depth of cut 299 design of machinability test 270 diamond-like CVD coating 14 die-cavity machining 498 die and mould milled surface texture 498 dierentially-pitched 472 diusion wear 334 dilution control 414 dimensionality 541 directionality of the grain-ow 206 direct numerical control (DNC) 51 direct sensing 532 discontinuous chip 60 dislocation 374 movement 488 displayed prole 135 disposal of cutting uid 417 DNC-link 234 double-negative cutting edge 156 double-positive cutting edge 156 double-tube ejector 115 down-cut milling 154 down-time 233 drill bushing tolerance 116 drilled hole slope angle 94 drilling 520 technology 88 drive curve mill 505 drunken thread 189 dry-machining 426 dual-contact 7/24 taper system 465 tool 465 dual-plane balance 478 dwell mark 449 dynamic-balancing 474 dynamic balance of toolholding assemblies 467 dynamics of twist drilling hole 96 dynamic stiness 74, 509 dynamic system 344 dynamic unbalance 230, 471 dynamometry 532 E eccentric machining 118 economical tool life (Te) 342 economics of: dry-; near-dry and wet- machining 427 edge clamping system 45 frittering 160 – – – – – – Subject Index 591 rounding 36 eective entering angle 45 eect of servo-lag and gain on corner milling 448 and gain whilst generating circular path 448 elastic distortion at contact 223 electrostatic precipitator 423 elimination of manual setting error 246 emulsication of tramp-oil 395 emulsier 396 emulsion 387 uid 398 end-cutting edge angle 317 endocrine hormone 418 entry-cycle 206 error 301 error-back-propagation algorithm 539 ethanol 522 Euclidean error 541 Eulerian technique 357 eutectic steel 488 evolution of cutting tool material 7 F face milling 151 engagement 160 facing 34 operation 34 fatigue 307, 336 feed and DOC 200 feed per tooth 166 feedrate 39 Fibre-bed system 423 Fick’s 1st law 334 Fick’s 2nd law 334 nes 226 nite element analysis (FEA) 223, 305, 355 nite element method (FEM) 328 ank infeed 193 wear 64, 334 ash-point 423 oated-reaming 139 oating reaming 139 ood coolant 515 oor vibration audit 530 ow stress 297 zone 354 uid machining strategy: dry; near-dry; or wet 425 ute design 105 – – – – – – – – – – uteless tap 189 y-cut milling 150 foaming property 390 force and temperature 357 forced vibration 295 form error 528 forming 34 fractionation 392 fracture 337 mechanic 336 free vibration 295 frictional condition 539 frictional eects during machining 353 frittering 94 front-and back-end 223 frustum-based face-mill 175 full-form 200 fully-automatic measurement of contour radii 252 G gain 299, 448 galling 185 galvanic corrosion 396 gang-milling 259 gas-spring support 453 gauge line 223, 453 grooving and recessing 71 group technology 241 gun-, or deep-hole drill 103 gun-drill 113 failure 115 rigidity rule 115 gun-drilling 96, 113 H h-value 165 hand-reamer 135 hand and machine tap 182 hand tap 182 hard-balancing 469 hard-milling – tool selection and replacement 514 hard-part machining 128, 507 milling 511 turning 508 hardness 507 harmonic 126 roundness 287 health and safety factors – concerning cutting uid operation and usage 418 heat aected layer (HAL) 360 – – – – – – – 592 Subject Index helical 96 chip formation 71 cutter 259 interpolation 203 wandering 94 helix angle 155 high-eciency particulate air lter 423 high-feed insert 66 high-pressure cooling (HPC) 386 high-pressure jet-assisted coolant delivery 383 high-speed machining (HSM) 408, 432 high-speed stee 507 high static and dynamic rigidity 230 high torque transmission 230 Hirth gear-tooth coupling mechanism 221 historical development of cutting uid 382 history of machine tool development 50 hm value-range 165 homogeneity of material 272 hoop-stress 287 hot hardness 6, 335 Hot Isostatic Pressing (HIP) 8 HSK dual-contact tooling 466 HSM chucks – for turning operation 462 dynamic balancing machine application 472 machine tool design consideration 434 problem of tool balance 469 research application 474 rotating dynamometry 493 toolholders/chucks 458 with non-orthogonal machine tools and robots 451 HSM dynamics acceleration and deceleration 445 servo-lag 446 HSS tool material 272 wear-rate test 274 HSS twist drill 107 human body 530 human skin 397 hybrid parameter 312 hybrid spindle 445 hydro-static bearing 509 performance 511 hydrodynamic wedge 387 hydrolytic stability 425 hysteresis 439 loop 344 – – – – – – – – – – – – – – – – – – I ideal cutting uid 387 in-cycle tool breakage detection 246 incident light image processing 252 incremental feeding 193 indexable drill 103, 107 indirect sensing 532 induction-hardened surface 156 initial, or primary wear 339 insert geometry 71 insert pocket 472 insert shape 45 insert size 47 interface pressure 54 interference t 462 interference ratio 203 intermittent cutting action 150 internal thread milling 206 introduction to surface texture parameter 305 Isosceles triangle 488 isotropic material 26 J jobber drill 94 jogging-down 245 just-in-time (JIT) 234 K Kanban 234 keyway positioning 256 kinematic 301 Knoop indentor 29, 364 knurling 209 Kurtosis parameter (Rku) 315 L lace cuts 514 lack of anity 6 Lagrangian FEA machining model 357 simulation machining modelling 357 Lagrangian methods 356 Lanchester boring bar 128 land 36 Lang’s chip-packing ratio 68 laser-controlled feedback 453 law of friction 353 lay 307 lead 195 lead time 263 least squares reference circle (LSC1) 492 – – Subject Index 593 lengthening eect 101 lights-out machining environment 230 limit and t 264, 462 limit gauge 223, 264 line-boring 133 linear plunging 206 line of balance 263 lobed-shape 287 lobing 287 location and restraint 160 logistic 238 logistical information and knowledge 238 longitudinal turning 34 look-ahead 450 looping 505 lubricity 395 M M2 HSS 8 machinability 270 strategy 280 machine checking gauge (MCG) 489 machine cleaning 411 machined cusp 36, 82 machined roundness 285 machined surface texture (Rt) 48, 305 machined surface topography 317 machine reaming 135 machine tap 186 machine tool 526 axis-orthogonality 287 compatibility 390 conguration 408 monitoring technique 531 optimisation 535, 537 machining and turning centre modular quick-change tooling 221 machining centre 150 machining modelling and simulation 350 machining simulation – validation 357 machining temperature 326 magnetic ‘active’ spindle 440 maintenance of the uid 414 manufacturing process envelopes 324 marine propeller manufacture 434 martensite 488 mass eect 191 material ratio curve (Rmr) 315 material removal rate 498 material requirement planning (MRP) 234, 243 maximum allowable chordal deviation 449 maximum production rate (Tq) 342 – – – – – – measurement of a complete tool station 246 measuring-cut time 218 mechanical advantage (MA) 224 mechanical fatigue cracking 336 mechanically aected layer (MAL) 360 meso-scale machining 524 metal-to metal contact 223 meter cut-o 308 micro-boring tool 523 micro-drill 520 back-taper 520 micro-drilling toolholder 523 micro-machine tool 525 micro-machining 524 micro-mill 522 micro-milling 523 micro-structural change 360 micro-tooling 518 material 520 microbiocide 397 MicroHole™ 250 microstructure test 273 mill/turn centre 150 operation 177 milled concavity 168 milled roundness – interpolated diameter 301 miller indices 30 milling 150, 522 closed-angle face 169 milling cutter approach angle 158 density 162 geometry 155 milling thin-wall 170 milling thin base 172 mineral oil 392, 423 synthetic, or semi-synthetic lubricant 392 minimum undeformed chip thickness 319 mixed-tipping 105 mode of deformation 101 modied ank infeed 193 modular quick-change tooling 212 modular tooling 118 monitoring, maintenance and testing of cutting uid – in use 411 monolithic diamond 530 morse taper 135 MoS2 super-glide coating 19 mounting and adjusting milling cutter 256 single-blade reamer 261 – – – – – – – – – – – 594 Subject Index MRPII 234 multi-functional uid 417, 423 tooling 79 multi-layer perceptron 539 multi-point form 200 multi-spindle drilling 110 multifacet drill 94 multiple-boring tool 124 N N-nitrosamine 422 nano-machine tool and its facilities 528 nano-machining 526 natural diamond 29 near-dry machining 426 nitride-hardening 478 non-contacting tool sensing 526 non-destructive testing (NDT) 367 non-lace cuts 514 Non-Uniform Rational Bezier-Spline (NURBS) 502 nose radius 48, 317 notch wear 335 notch wear on insert’s leading edge 335 numerically-controlled (NC) machine 50 NURBS-interpolation 502 O oblique cutting force 39 oblique machining 56 ogive error 528 oil-drum skid 409 on-line tool condition monitoring – using neural networks’ 538 one-hit machining 177, 216 operating condition 242 optimisation 4 optimum/economic batch size 240 orthogonal array factor 282 cutting force 39, 41 machining 54 out-of-roundness 135 P P/M density 277 parabolic 36 curved surface 496 interpolation 496 parallel cuts 514 part families 220 – – – – – – – parting-o 74 operation 75 part orientation and register 107 passive force (Fp) 105 passive system 344 Peak 315 pearlitic structure 488 Pearson coecient 324 product moment correlation coecient 324 peripheral milling cutter approach angle 163 radial 152 tangential 153 perishable and capital equipment review 241 permissible exposure level (PEL) 420 photo-elastic stress analysis 305 photosensitisation 420 pH reading 416 physical asset 390 physical property test 274 pick-feed 496 piece-work system 52 Piezoelectric dynamometer 344 eect 344 storage 345 pioneering work in metal cutting 51 pioneers in metal cutting 50 pitch 182, 195 plain carbon steel 7 plan approach angle 41 planned maintenance scheduling 390 plano-mill 150 plastic deformation 335 ploughing-eect 509 pneumatic spindle 440 pocketed feature 153 pocket milling 169 poly-crystalline diamond (PCD) 25, 507 Porcupine cutter 156 positive/negative cutting edge 156 power spectral density 541 power spectrum analysis 291 practical testpiece – for CNC application 275 precision 518 presetting o the machine tool 254 presetting on the machine tool non-contacting tool setting 248 tool contacting 245 primary function of a cutting uid 383 primary irritation 420 – – – – – – – – – – – Subject Index 595 primary shear zone 103 principle of chip-breaking 68 process capability 64, 334 process monitoring 532 product stability 416 product testing 406 prole 307 proling 34 programmable and xed steadies 291 programmed block 449 progressive, or secondary wear 339 proving-ring 344 pull-threading 193 pull stud pressure variation 228 pure ceramic 21 push threading 193 Q qualied tool 245 qualied tooling 118, 226 quasistatic measurement element 345 R radial-ground top rake 71 radial chip-thinning 165 radial deection (∆T) 131 radial force 41 radial infeed 193 radial infeed technique 193 radially-adjustable machine reamers 139 radial play 139 radial runout 103 radial step-over 514 radial top rake 73 radius 36 ranking’ – non-machining test 273 ranking machining test 272 rapid facing test 272 rate of heat generation 328 rational equation 504 rationalisation 2 re-circulating ballscrew 252 re-cutting eect 166 reactive ion plating 17 reactive sputtering 17 reaming 135 problems and their remedies 142 reaming technology 133 recirculating ballscrew 50 recutting eect 515 reduced peak height 313 – reference material 272 refractive index of the air 530 refractometer operation 414 regenerative chatter 74 reliability-centred maintenance (RCM) 390 residual stress 357 deformation 362 in machined surface 360 resistance to oxidation 7 resistance to thermal shock 6 resonance 295 resonant frequency 439 restmilling operation 498 retraction striae 105 return on investment (ROI) 116, 342 rheology 58 rigidity rule 94 rigidity square rule 301 rippa-cutter 156 robotic machining 456 roll shearing 172 root mean square (rms) 312, 347 rotary and frustum-based milling cutter 172 rotating centre 291 rotating insert cutting speed 172 rotating insert face-mill 172 roughness 307 roundness testing machine 492 ruling section 189 S safety factor 336 sampling length 308 sawdust 410 scanning electron microscopes’ (SEM’s) 480 scheduling of part 151 sculptured surface machining cutter simulation 505 with NURBS 502 secondary machining 270 secondary shear zone 103 segmented chip 60 selecting the correct cutting uid 407 self-excitation vibration, or chatter 295 self-excited vibration 74 self-opening dies 191 semi-qualied tool 245 semi-synthetic uid 398 lubricant 392 – – – – – – – 596 Subject Index sensitisation 420 sequential machining 505 surface machining 505 servo-gain 448 servo-lag 448 setting-up time 218 setting block 246 Shewart charting techniques 334 short-hole drilling 96 sialon 22 side-cutting angle 317 single-plane unbalance 471 single-tube system drill 115 sister tooling 5, 213, 226 Skewness (Rsk, Wsk, Psk) and Kurtosis (Rku, Wku, Pku) parameter 313 Skewness parameter (Rsk) 315 skin condition 420 slab-mills 156 slip-line eld modelling 355 slot-drilling 153 SN curves 336 Soderberg diagram 336 sodium nitrate 418 solid carbide twist drill 107 solution 387 soybean oil 423 spacing parameter 312 spade drill 103 Spanzipfel 319 specic cutting force 41 speed-increaser 489 speed analyser 300 speed ratio 204 spindle camber/tilt 166 spindle design 465, 466 spindle imbalance 287 spindle nose dri 228 spindle taper 465 spline 504 split-point 94 spot-facing 142 spring-cut 201, 295 square-shoulder cutter 160 stabiliser and solubiliser 396 stability lobe diagram (SLD) 300 Stabler’s law 88 staggered-toothed side-and-face cutter 155 stair-case prole 498 stand-alone machine tool 234 – – static unbalance 469 statistical variability 76 step-boring 124 step-over distance 496 step-turning test 274 stereometric artefact conceptual design 488 machining trial 488 stick-slip 330, 436 sticking region 354 stiction 330, 436 stochastic process 308 straddle milling 259 strain 274 stratication eect 528 stress-corrosion cracking (SCC) 368 stress aected layer (SAL) 360 stress pattern 305 striation 368 eect 368 sump-life 390 super-nishing 331 supercritical speed 432 supply-chain management 255 surface 308 condition 360 crack and white-layer 367 displacement 360 engineering 308 gouging 505 sub-surface micro hardness 360 tension 382 topography 168 surface integrity 96 manipulation 374 of machined component 360 sub-surface feature 373 synchronous milling method 203 synthetic diamond 25 synthetic lubricant 392 system-learning 534 T tacky, or gummy deposit 391 tagged-tooling 219, 531 Taguchi orthogonal array 282 tangential deection (∆R) 131 tangential force 39 taper-sectioning and micro-hardness assessment 362 taper-turning test 274 – – – – – – – – – – – – – – Subject Index 597 taper reamer 261 taper turning 34 tapping depth 186 tapping size 182 target analogy 518 Taylor’s theory of gauging 264 tool life equation 273 telescopic line-boring tool 133 telescoping ballbar 482 temperature and thermal eect 357 in twist drilling 101 tempering 488 ternary manufacturing envelopes (TME’s) 326 testing for concentration level 414 for pH level 416 thermal and frictional modelling of the cutting process 355 condition 525 cracking 336 eect 525 fatigue crack 336 history 273 movement 248 shock/fatigue 426 thermal diusivity (K/ρc) 103 thermographic equipment 516 thermography 516 thin coats-v-thick coat 426 thread 182 chasing die head 191 nishing and close tolerancing 201 helix angle 195 milling 203 prole generation 198 turning 191 threading dies 189 threading insert inclination 195 threading insert top face geometry 196 threading shimming 195 threading turning 200 thread rolling 206, 209 technique 209 three-jaw chuck – clamping force 509 three-roll radial rolling 209 titration 416 method 416 tool-card indexing system 2 – – – – – – – – – – – – – – – – – – – – – – tool-changing time 218 tool-condition monitoring – with feed-force sensor 532 tool-life diagram 340 tool-oset measurement 532 tool – acoustic emission monitoring 539 tool – condition monitoring system 541 tool – force monitoring 539 tool – sensor fusion and multi-sensor integration 539 tool – vibration monitoring 539 tool adaptor system 216 tool and sleeve hydraulic design 460 mechanical interface 458 thermal and cryogenic design 460 tool breakage detection 532 time 534 tool coating chemical vapour deposition (CVD) 14 physical vapour deposition (PVD) 17 tool crash 534 tool driing 334 tool force 39 toolholder design 465 size and type 45 tool identication 531 tooling requirement for machining centre 225 for turning centre 216 tool life 337 monitoring 532 tool management 233 infrastructure 238 system 244 tool material 49 for hardened steel milling 500 tool nose radius 62 tool presetting equipment 245 tool push-o 124 toolshank design and gripping pressures 458 tool store and its presetting facility 261 tool wear 64, 331 analysis 357 and life 330 state 541 tooth prole and dimension 203 torque (M) 101 Torque-Controlled Machining (TCM) 321, 532, 535 Total Productive Maintenance (TPM) 390 – – – – – – – – – – – – – – – – – 598 Subject Index touch-trigger probe 246 toughness 7 trail-line 105 tramp oil tolerance 391 transient surface 75, 294 transversal, or face grooving 73 tresca’s visio-plasticity model 51 triazine biocide 418 tribology 317 triple-contact tool 466 tumour and cancerous eect 422 tuned boring bar 127 tungsten 8 turned roundness – harmonic and geometric 291 twist drill 96 fundamental 88 interface temperature 103 two-roll axial rolling 209 tangential rolling 209 type of cutting uid 387 U UHSM cutting trials 480 face-milling cutter design 477 trepanning xture design 484 trepanning operation 486 turning strategy 482 turning trend 484 ultra-high speed face-milling design and development 474 trepanning operation 484 turning operation 480 ultra-precision machining 516 uncertainty budget 301 uncertainty of machine tool positioning 439 undeformed chip thickness 41, 99 universal measuring machine – for checking tooling 252 unqualied tools 245 – – – – – – – – – – – – – up-cut and down-cut milling 153 milling 154 V V-form 200 variable-rate machining test 274 variance 307 vegetable oil 423 vegetable oil-based MWF 423 Vendor Rating (VR) 255 Venturi meter 411 Venturi principle 411 Vickers indentor 364 viscosity 331, 423 Viscosity Index (VI) 331, 423 W water-based uid additive 418 water-supply compatibility 391 water hardness levels 397 waterline milling 170 water quality 397 waviness 307 web 94 web-thinning 96 wet- and dry-machining – the issues and concern 425 wheatstone bridge resistance circuits 344 white-layer 368 wiper blade 64 wiper insert 66 witness mark 511 word-address format 451 workpiece compatibility 390 Y yield, or permanent deformation 508 yield-point 274 Z Z-axes 228 – – Subject Index 599 . machining 52 4 metal-to metal contact 223 meter cut-o 308 micro-boring tool 52 3 micro-drill 52 0 back- taper 52 0 micro-drilling toolholder 52 3 micro-machine tool 52 5 micro-machining 52 4 micro-mill. feed-force sensor 53 2 tool- life diagram 340 tool- oset measurement 53 2 tool – acoustic emission monitoring 53 9 tool – condition monitoring system 54 1 tool – force monitoring 53 9 tool – sensor. 414 cutting force 201 dynamometry 343 cutting force (∆Fc) 1 05 cutting insert edge preparation 36 shape 1 05 cutting speed 200 cutting stiness (Ks) 297, 299 cutting time 341 cutting tool