Metal Cutting

Theory, Selection, and Design

5th Edition - April 18, 2025
Imprint: Butterworth-Heinemann
Authors: Edward M. Trent, Paul K. Wright, Peter A. Dearnley
Language: English
Paperback ISBN:
9 7 8 - 0 - 3 2 3 - 9 9 1 5 5 - 1
eBook ISBN:
9 7 8 - 0 - 3 2 3 - 9 9 1 5 7 - 5

Metal Cutting, Fifth Edition builds upon the classic work that has for decades been the go-to reference for individuals working in the area of metal cutting. This revised editio… Read more

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Metal Cutting, Fifth Edition builds upon the classic work that has for decades been the go-to reference for individuals working in the area of metal cutting. This revised edition, divided into four parts, features an extensive new chapter on coated cutting tools and updated and expanded chapters on ceramic cutting tools and machinability. A discussion of wear mechanisms and their governing equations is included, as are updates on tool micro examination, use of the quick-stop method, and tool temperature determination. Each chapter begins with a comprehensive bullet point summary and contents. The book will be useful for those studying and teaching courses on metal cutting and machining processes at the advanced undergraduate and graduate levels in universities as well as professional materials scientists and mechanical engineers in industrial manufacturing sectors centered on automotive and aerospace component production.

Metal Cutting
Cover image
Title page
Table of Contents
Copyright
Dedication
Preface
Part I: The Basics
Chapter 1 Introduction
Abstract
Keywords:
1.1 The Metal Cutting (or Machining) Process
1.2 A Short History of Machining
1.3 Machining and the Global Economy
1.4 Summary and Conclusions
1.4.1 Economics
1.4.2 Sociology
1.4.3 Technology
References
Chapter 2 Metal Cutting Operations and Terminology
Abstract
Keywords:
2.1 Summary Points
2.2 Introduction
2.3 Turning or Turn-Cutting
2.4 Boring
2.5 Drilling
2.6 Facing
2.7 Forming and Parting Off
2.8 Milling or Mill-Cutting
2.9 Shaping and Planing
2.10 Broaching
2.11 Final Perspective
References
Bibliography (Also See Chapter 16)
Chapter 3 The Essential Features of Metal Cutting
Abstract
Keywords
3.1 Summary Points
3.2 Introduction
3.3 The Chip
3.4 Techniques for Studying Chip Formation
3.5 Chip Shape
3.6 Chip Formation
3.7 The Chip/Tool Interface
3.8 Chip Flow Under Conditions of Seizure
3.9 The Built-Up Edge
3.10 Machined Surfaces
3.11 Conclusions
References
Chapter 4 Forces and Stresses in Metal Cutting
Abstract
Keywords
4.1 Summary Points
4.2 Introduction
4.3 Forces and Stresses on the Primary Shear Plane
4.4 Forces in the Flow Zone
4.5 The Primary Shear Plane and Minimum Energy Theory
4.5.1 Merchant’s shear “plane” analysis
4.5.2 Oxley’s shear “zone” analysis
4.5.3 Rowe and Spick’s approximate analysis
4.6 Forces in Cutting Metals and Alloys
4.7 Stresses in the Tool
4.8 Stress Distribution
4.8.1 Introduction
4.8.2 Experiments with split tools – Method 1
4.8.3 Experiments with tools of different strengths – Method 2
4.8.4 Experiments with photo-elastic polymers – Method 3
4.8.5 Experiments with photo-elastic sapphire – Method 4
4.8.6 Normal stress distribution: Typical results
4.8.7 Shear stress distribution: Typical results
4.8.8 General summary of photo-elasticity work and stress analyses
4.8.9 A special note on practical machining with ceramics and diamond tools
4.9 Conclusions
References
Chapter 5 Heat in Metal Cutting
Abstract
Keywords:
5.1 Summary Points
5.2 Introduction
5.3 Heat in the Primary Shear Zone
5.4 Heat at the Tool/Work Interface
5.4.1 Interface temperatures with a BUE
5.4.2 Interface temperatures with a flow zone
5.4.3 Calculation of interface temperatures with a flow zone
5.5 Heat Flow at the Tool Clearance Face
5.6 Heat in Areas of Sliding
5.7 Methods of Tool Temperature Measurement
5.7.1 Tool/work thermocouple
5.7.2 Inserted thermocouples
5.7.3 Radiation methods
5.7.4 Changes in hardness and microstructure in steel tools
5.8 Measured Temperature Distribution in Tools
5.9 Relationship of Tool Temperature to Speed
5.10 Relationship of Tool Temperature to Tool Design
5.11 Conclusions
References
Part II: The Tool Materials
Chapter 6 High-Speed Steels
Abstract
Keywords:
6.1 Summary Points
6.2 Background and History
6.3 High-Carbon Steel Tools
6.4 High-Speed Steels
6.5 Structure and Composition
6.5.1 Tungsten and molybdenum
6.5.2 Carbon
6.5.3 Chromium
6.5.4 Vanadium
6.5.5 Cobalt
6.6 Properties of High-Speed Steels
6.7 Wear Mechanisms of Uncoated High-Speed Steel Tools
6.7.1 How to examine used cutting tools
6.7.2 Superficial (discrete) plastic deformation by shear at high temperature
6.7.3 Plastic deformation of the cutting edge under compressive stress
6.7.4 Dissolution/diffusion wear
6.7.5 Attrition wear (plucking or grain pull-out)
6.7.6 Abrasive wear
6.7.7 Wear under sliding conditions
6.7.8 Summary
6.8 Tool-Life Testing
6.9 Conditions of Use
6.10 Coated High-Speed Steel Tools
6.11 Other Developments
6.12 Concerning Powder Metallurgy (PM) High-Speed Steel
6.13 Conclusions
References
Chapter 7 Uncoated Cemented Carbides
Abstract
Keywords:
7.1 Summary Points and Background
7.2 Structures and Properties of Cemented Carbides
7.3 Straight-Grade Tungsten Carbide-Cobalt Alloys (WC-Co)
7.3.1 Background
7.3.2 Stress-strain behavior
7.3.3 Fracture strength
7.3.4 Fracture toughness
7.3.5 Hardness (H), yield strength (σy), and 0.2% proof strength (σ0.2%)
7.3.6 Young’s modulus and the rules of mixtures
7.3.7 Density
7.3.8 Further comments on the hardness (H) of cemented carbides
7.4 Steel Cutting Grade WC-γC-Co Alloys
7.4.1 General perspective
7.4.2 More concerning microstructure, composition, and properties of WC-γC-Co alloys compared to WC-Co alloys
7.5 Elevated Temperature and Other Thermal Properties
7.5.1 High-temperature mechanical properties of WC-Co and WC-γC-Co alloys
7.5.2 Other thermal properties of WC-Co and WC-γC-Co alloys
7.6 Metal Removal Rates and Machining Charts
7.7 Wear Mechanisms of Uncoated Cemented Carbides
7.7.1 Superficial (discrete) plastic deformation by shear at high temperature
7.7.2 Plastic deformation of the cutting edge under compressive stress
7.7.3 Diffusion wear or dissolution/diffusion wear (DDW)
7.7.4 Attrition wear (plucking or grain pull-out)
7.7.5 Abrasive wear
7.7.6 Fracture
7.7.7 Thermal fatigue and thermal stress
7.7.8 Notch wear (NW) or grooving wear (under sliding conditions)
7.7.9 Summary
7.8 Titanium Cermets
7.9 Laminated Carbide Tools
7.10 Techniques of Using Cemented Carbides for Cutting
7.10.1 Early methods using brazed-on carbide tips
7.10.2 The transition to throw-away tool tips or indexable inserts
7.11 Overall Summary
References
Chapter 8 Coated Cutting Tools
Abstract
Keywords
8.1 Summary Points and Background
8.2 Coating Technologies
8.2.1 Chemical vapor deposition (CVD)
8.2.2 Plasma-assisted CVD (PACVD), also termed plasma-enhanced CVD (PECVD)
8.2.3 Physical vapor deposition (PVD)
8.3 Wear Mechanisms and Wear Rates of Coated Cemented Carbides
8.3.1 Background
8.3.2 Rake face and flank face wear rates
8.3.3 Rake face and flank face wear mechanisms
8.3.4 Coating breakthrough and coated tool wear patterns
8.3.5 Textured CVD-Al2O3 coated cemented carbides
8.3.6 Adhesive fracture wear (AFW) on the rake and flank faces
8.3.7 Notch wear of coated cemented carbides
8.3.8 Notch wear of coated and uncoated cermets
8.3.9 Thermal stress
8.4 Summary
8.5 Terminology
References
Chapter 9 Alumina (Al2O3)-Based Ceramics and Sialons
Abstract
Keywords:
9.1 Summary Points
9.2 Background
9.3 Alumina (Al2O3)-Based Ceramics
9.3.1 Alumina ceramics
9.3.2 Zirconia-toughened alumina (ZTA) composites
9.3.3 Alumina-titanium carbide (Al2O3-TiC) and related mixed ceramic composites
9.3.4 Alumina-silicon carbide whisker (Al2O3-SiCw) reinforced composites
9.3.5 Cutting edge geometry
9.4 Sialon Ceramics
9.4.1 Microstructure and properties of sialons
9.4.2 Further aspects of sialon tool wear
9.4.3 Sialons with an additional phase or surface modification
9.5 Summary
References
Chapter 10 Ultrahard Tool Materials
Abstract
Keywords:
10.1 Summary Points and Background
10.2 Cubic Boron Nitride (CBN)
10.2.1 General properties of CBN
10.2.2 Machining performance of CBN
10.3 Diamond, Synthetic Diamond, and Diamond-Coated Cutting Tools
10.3.1 General properties of diamond
10.3.2 Synthetic diamond and polycrystalline diamond (PCD) composites
10.3.3 Machining performance of synthetic PCD diamond tools
10.3.4 CVD polycrystalline diamond- and DLC-coated tools
References
Part III: Applying the Tools
Chapter 11 Machinability of Steels and Cast Irons
Abstract
Keywords
11.1 Summary Points
11.2 Defining Machinability (MTY)
11.2.1 Temperature effects
11.2.2 Structure of this chapter and Chapter 12
11.3 Commercially Pure Iron
11.4 Steels: Alloy Steels and Heat Treatments
11.4.1 Influence of alloying elements on the forces and stresses on the tool
11.4.2 Relative MTY of steel
11.4.3 Combined influence of alloying, heat treatment, stress, and temperature
11.4.4 BUE effects
11.5 Free Cutting Steels
11.5.1 Economics
11.5.2 Resulfurized free cutting steels
11.5.3 The role of lead additions
11.5.4 Other factors that influence the machinability of some steels
11.6 Hard Steels and Cast Irons (Room Temperature HV > 450 kg/mm2)
11.7 Austenitic Stainless Steels
11.7.1 Standard austenitic and duplex stainless steels
11.7.2 Free cutting stainless steels
11.8 Cast Iron
11.8.1 Gray cast iron microstructures and chip formation
11.8.2 Aspects of machining gray cast irons
11.8.3 Alloy and chilled cast irons
11.9 Conclusions
References
Chapter 12 Machinability of Other Metals
Abstract
Keywords:
12.1 Summary Points
12.2 Magnesium
12.3 Aluminum and Aluminum Alloys
12.3.1 Introduction
12.3.2 Machinability of aluminum-silicon (Al-Si) alloys
12.3.3 Aluminum alloys versus commercially pure aluminum
12.3.4 Some industrial/practical constraints
12.3.5 Free machining aluminum alloys
12.3.6 Summary on aluminum alloys
12.4 Copper, Brass, and Other Copper Alloys
12.4.1 Introduction
12.4.2 Machinability of conventional brasses
12.4.3 Machinability of free machining brass
12.4.4 Environmental concerns
12.4.5 Aluminum bronze
12.4.6 Cupro-nickel alloys
12.4.7 Summary on copper, brass, and copper-based alloys
12.5 Nickel and Its Alloys
12.5.1 Commercially pure nickel
12.5.2 Nickel alloys
12.6 Titanium and Titanium Alloys
12.6.1 Background summary
12.6.2 Chip formation
12.6.3 Commercial purity titanium (CP-Ti)
12.6.4 Titanium alloys
12.6.5 Alternative tool materials for machining titanium alloys
12.7 Zirconium
12.8 Conclusions
References
Chapter 13 Coolants and Lubricants
Abstract
Keywords
13.1 Summary Points
13.2 Introduction
13.2.1 Cooling effects of water-based cutting fluids
13.2.2 Lubricating effects of neat cutting oil fluids
13.2.3 Selection for different processes and work material types
13.2.4 Dry versus water-based versus oil-based fluids
13.3 Coolants
13.3.1 Importance of fluid jet and nozzle location
13.3.2 Machining steel with coolants
13.3.3 Machining commercially pure nickel with coolants
13.3.4 Practical considerations with coolants
13.3.5 Potential use of high-pressure jets and carbon dioxide
13.3.6 A special experiment with liquid nitrogen
13.4 Lubricants
13.4.1 Conditions of seizure impede the action of external lubricants
13.4.2 Lubrication at the periphery of contact or during intermittent cutting
13.4.3 Experiments in controlled atmospheres
13.4.4 Importance of “natural air” as a lubricant
13.4.5 Importance of nitrogen in protecting tool surfaces
13.4.6 Summarizing the role of air in cutting and implications for dry cutting
13.4.7 Extreme pressure additives in lubricants
13.4.8 Surface finish
13.4.9 Influence of cutting speed and tool material type
13.5 Conclusions on Coolants and Lubricants
13.5.1 General observations
13.5.2 Trends toward dry cutting
13.5.3 Recommendations
References
Chapter 14 High-Speed Machining
Abstract
Keywords:
14.1 Summary Points
14.2 Introduction to High-Speed Machining
14.3 Economics of High-Speed Machining
14.4 Brief Historical Perspective
14.5 Influence of Increasing Speed on Chip Type
14.5.1 The main chip types
14.5.2 Transition from type C to type D chip forms
14.6 Austenitic Stainless Steel
14.6.1 Overview
14.6.2 Photomicrographs of quick stops
14.6.3 Proposed mechanism for type D segmented chips in stainless steel
14.6.4 Summary of the above effects
14.7 Hardened and Tempered AISI 4340
14.7.1 Overview
14.7.2 Conditions in the primary zone when machining AISI 4340 steel
14.8 Aerospace Aluminum and Titanium
14.8.1 Overview
14.8.2 Cutting Ti-6A1-4V at high speeds
14.8.3 Cutting aluminum alloys at high speeds
14.9 Discussion and Recommendations
14.9.1 Segmented chip forms in high-speed machining
14.9.2 Tool forces
14.9.3 Tool wear
14.10 Conclusions
References
Part IV: Student Tasks and Bibliography
Chapter 15 Student Exercises
Abstract
Keywords
15.1 Part A – Questions Are Based on Section 7.2 of Chapter 7
15.2 Part B – Questions Based on Other Chapters
15.3 Part C – A Tutorial on Machining Economics
Chapter 16 Bibliography and Selected Web-Sites
16.1 Introduction
16.2 Texts and on Metal Cutting and Tool Materials
16.3 General Texts That Include Metal Cutting
16.4 Selected Texts on Rapid Prototyping
16.5 Selected Texts on Forming
16.6 Suggested Background Reading
16.7 Recommended Journals
16.8 Web-Site Resources and Technical Bulletins of Tool Material Suppliers
Index

Edward M. Trent

Edward Moor Trent was born in England and was the first to describe the diffusion wear mechanisms in tungsten-carbide-cobalt cutting tools. This work was the foundation for new grades of carbide for cutting steels, and subsequently for the development of coated cutting tools. Trent was a prominent lecturer in the Industrial Metallurgy Dept. at Birmingham University and was awarded the "Hadfield Medal" by the Iron and Steel Institute in recognition of his contributions to metallurgy. His accomplishments are highly regarded among professionals in the field today. Founding author of this book.

Affiliations and expertise

Former Lecturer, Industrial Metallurgy Department, Birmingham University, UK

Paul K. Wright

Paul Kenneth Wright (PhD) is prominent in the field and was formerly a professor of mechanical engineering and co-chairman of the Management of Technology Program at the University of California/Berkeley School of Engineering. He has written numerous articles for journals, conferences, and symposiums, as well as coauthored "Manufacturing Intelligence," with D.A. Bourne. In addition, he has served as a consultant and has been involved in many professional organizations.

Affiliations and expertise

Professor of Mechanical Engine, University of California,, Berkeley, USA

Peter A. Dearnley

Peter Albany Dearnley (PhD) formerly: Visiting Professor University of Southampton, UK, Senior Lecturer University of Leeds, UK.; Senior Lecturer University of Auckland, NZ., Senior Research Associate University of Cambridge, Research Fellow University of Birmingham, Research Technologist Sandvik Hard Materials Ltd, UK. Awarded (with Mr A N Grearson of Sandvik Hard Materials) the 1987 "Pfeil Medal" by the Institute of Materials, in recognition of their major contribution to understanding cutting tool wear mechanisms when machining titanium alloys.

Affiliations and expertise

Visiting Professor University of Southampton, UK, Senior Lecturer University of Leeds, UK.; Senior Lecturer University of Auckland, NZ., Senior Research Associate University of Cambridge, Research Fellow University of Birmingham, Research Technologist Sandvik Hard Materials Ltd, UK

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Metal Cutting

Theory, Selection, and Design

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Edward M. Trent

Paul K. Wright

Peter A. Dearnley

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