Machining dynamics : fundamentals, applications and practices

Title:

Series:

Springer series in advanced manufacturing

Publication Information:

Berlin : Springer, 2009

Physical Description:

xviii, 328 p. : ill. ; 24 cm.

ISBN:

9781846283673

Subject Term:

Machine-tools -- Dynamics

Machining

Added Author:

Cheng, Kai

Available:*

Library	Item Barcode	Call Number	Material Type	Item Category 1	Status
Searching... PSZ JB	30000010193932	TJ1185 M324 2009	Open Access Book	Book	Searching... Unknown
Searching... PSZ JB	30000010183049	TJ1185 M324 2009	Open Access Book	Book	Searching... Unknown

Machining dynamics are vital to the performance of machine tools and machining processes in manufacturing. Advances in computational modelling, sensors, diagnostic equipment and analysis tools, 3D surface metrology and manufacturing science are providing a new perspective on the machining process.

Written by experts in each field, this book discusses the state-of-the-art applications, practices and research in machining dynamics. Part 1 presents the basic theory, analysis and control methodology in addition to detailed modelling and diagnostic techniques, while Part 2 focuses on the applications of machining dynamics in machining processes such as turning, grinding, gear machining and non-traditional machining.

Advanced undergraduate and postgraduate students studying manufacturing engineering and machining technology will find this book a comprehensive introduction. Manufacturing engineers, production supervisors, planning and application engineers and designers will find it a useful reference.

Author Notes

Professor Kai Cheng holds the chair professorship in Precision Engineering at Leeds Metropolitan University. His current research interests focus on the design of precision machines and instruments; nano-/micro-machining; machining dynamics and control; precision manufacturing; and digital manufacturing and enterprise technologies. Professor Cheng has published over 160 papers in international journals and refereed conferences, authored/edited four books and contributed six book chapters. He is Associate Editor (Europe) for Springer's International Journal of Advanced Manufacturing Technology.

His BEng (Hons) and MSc degrees were obtained from the Harbin Institute of Technology and he has a PhD from Liverpool John Moores University. He worked as a senior lecturer in Glasgow Caledonian University before joining Leeds Metropolitan University. Professor Cheng is a fellow of the IEE and the IMechE, and a member of the Euspen. He is the leader of the Advanced Manufacturing Technology Research Group, which is currently working on a number of research projects funded by the UK Research Councils, EU 6th Framework Program, KTP Program, DTI (UK), and the industry. The group has a record of international excellence in the areas of precision machine design, nano-/micro-machining and digital manufacturing.

Reviews 1

Choice Review

Machining dynamics is an important area for the advancement of national economies. The advent of computer-controlled universal machining centers and five-axis milling machines, among other advanced computer numerical control (CNC) machine tools, are greatly increasing worldwide manufacturing productivity. This book is the work of 16 authors. Seven are from England, six are from Asia, two from Brazil, and one from Portugal; there is no direct representation from US, Canadian, or western European centers of modern machining dynamics. Contributors cover grinding, milling, dynamics and control, tool wear, turning, and precision machines. This work can be used as an introduction to some of the science and engineering that lies at the foundation of the operation of these machine tools. Summing Up: Recommended. Upper-division undergraduates, graduate students, researchers, and faculty in manufacturing engineering. A. M. Strauss Vanderbilt University

List of Contributors	p. xvii
1 Introduction	p. 1
1.1 Scope of the Subject	p. 1
1.2 Scientific and Technological Challenges and Needs	p. 2
1.3 Emerging Trends	p. 4
References	p. 6
2 Basic Concepts and Theory	p. 7
2.1 Introduction	p. 7
2.2 Loop Stiffness within the Machine-tool-workpiece System	p. 7
2.2.1 Machine-tool-workpiece Loop Concept	p. 7
2.2.2 Static Loop Stiffness	p. 8
2.2.3 Dynamic Loop Stiffness and Deformation	p. 9
2.3 Vibrations in the Machine-tool System	p. 10
2.3.1 Free Vibrations in the Machine-tool System	p. 10
2.3.2 Forced Vibrations	p. 13
2.4 Chatter Occurring in the Machine Tool System	p. 15
2.4.1 Definition	p. 15
2.4.2 Types of Chatters	p. 16
2.4.3 The Suppression of Chatters	p. 16
2.5 Machining Instability and Control	p. 17
2.5.1 The Conception of Machining Instability	p. 17
2.5.2 The Classification of Machining Instability	p. 19
Acknowledgements	p. 19
References	p. 19
3 Dynamic Analysis and Control	p. 21
3.1 Machine Tool Structural Deformations	p. 21
3.1.1 Machining Process Forces	p. 22
3.1.2 The Deformations of Machine Tool Structures and Workpieces	p. 30
3.1.3 The Control and Minimization of Form Errors	p. 39
3.2 Machine Tool Dynamics	p. 43
3.2.1 Experimental Methods	p. 43
3.2.2 The Analytical Modelling of Machine Tool Dynamics	p. 47
3.3 The Dynamic Cutting Process	p. 54
3.3.1 Mechanic of Dynamic Cutting	p. 55
3.3.2 The Dynamic Chip Thickness and Cutting Forces	p. 59
3.4 Stability of Cutting Process	p. 63
3.4.1 Stability of Turning	p. 64
3.4.2 The Stability of the Milling Process	p. 68
3.4.3 Maximizing Chatter Free Material Removal Rate in Milling	p. 74
3.4.4 Chatter Suppression-Variable Pitch End Mills	p. 79
3.5 Conclusions	p. 82
References	p. 83
4 Dynamics Diagnostics: Methods, Equipment and Analysis Tools	p. 85
4.1 Introduction	p. 85
4.2 Theory	p. 86
4.2.1 An Example	p. 88
4.2.2 The Substructure Analysis	p. 90
4.3 Experimental Equipment	p. 92
4.3.1 The Signal Processing	p. 92
4.3.2 Excitation Techniques	p. 93
4.3.3 The Measurement Equipment	p. 93
4.3.4 Novel Approaches	p. 94
4.3.5 In-process Sensors	p. 96
4.3.6 Dynamometers	p. 96
4.3.7 The Current Monitoring	p. 97
4.3.8 The Audio Measurement	p. 97
4.3.9 Capacitance Probes	p. 97
4.3.10 Telemetry and Slip Rings	p. 98
4.3.11 Fibre-optic Bragg Grating Sensors	p. 98
4.4 Chatter Detection Techniques	p. 98
4.4.1 The Topography	p. 100
4.4.2 The Frequency Domain	p. 100
4.4.3 Time Domain	p. 105
4.4.4 Wavelet Transforms	p. 109
4.4.5 Soft Computing	p. 110
4.4.6 The Information Theory	p. 111
4.5 Summary and Conclusions	p. 111
Acknowledgements	p. 112
References	p. 112
5 Tool Design, Tool Wear and Tool Life	p. 117
5.1 Tool Design	p. 118
5.1.1 The Tool-workpiece Replication Model	p. 118
5.1.2 Tool Design Principles	p. 120
5.1.3 The Tool Design for New Machining Technologies	p. 123
5.2 Tool Materials	p. 124
5.2.1 High Speed Steel	p. 124
5.2.2 Cemented Carbide	p. 124
5.2.3 Cermet	p. 125
5.2.4 Ceramics	p. 125
5.2.5 Diamond	p. 126
5.2.6 Cubic Boron Nitride	p. 127
5.3 High-performance Coated Tools	p. 127
5.3.1 Tool Coating Methods	p. 128
5.3.2 The Cutting Performance of PVD Coated Tools	p. 129
5.3.3 The Cutting Performance of CVD Coated Tools	p. 132
5.3.4 Recoating of Worn Tools	p. 133
5.4 Tool Wear	p. 133
5.4.1 Tool Wear Classification	p. 134
5.4.2 Tool Wear Evolution	p. 136
5.4.3 The Material-dependence of Wear	p. 138
5.4.4 The Wear of Diamond Tools	p. 139
5.5 Tool Life	p. 142
5.5.1 The Definition of Tool Life	p. 142
5.5.2 Taylor's Tool Life Model	p. 142
5.5.3 The Extended Taylor's Model	p. 144
5.5.4 Tool Life and Machining Dynamics	p. 145
References	p. 148
6 Machining Dynamics in Turning Processes	p. 151
6.1 Introduction	p. 151
6.2 Principles	p. 151
6.2.1 The Turning Process	p. 153
6.3 Methodology and Tools for the Dynamic Analysis and Control	p. 154
6.4 Implementation Perspectives	p. 155
6.5 Applications	p. 156
6.5.1 The Rigidity of the Machine Tool, the Tool Fixture and the Work Material	p. 156
6.5.2 The Influence of the Input Parameters	p. 162
6.6 Conclusions	p. 164
References	p. 164
7 Machining Dynamics in Milling Processes	p. 167
7.1 Introduction	p. 167
7.1.1 Forced Vibration	p. 167
7.1.2 Self-excited Vibration	p. 168
7.1.3 The Scope of This Chapter	p. 169
7.1.4 Nomenclature in This Chapter	p. 170
7.2 The Dynamic Cutting Force Model for Peripheral Milling	p. 171
7.2.1 Oblique Cutting	p. 172
7.2.2 The Geometric Model of a Helical End Mill	p. 173
7.2.3 Differential Tangential and Normal Cutting Forces	p. 174
7.2.4 Undeformed Chip Thickness	p. 175
7.2.5 Differential Cutting Forces in X and Y Directions	p. 178
7.2.6 Total Cutting Forces in X and Y Directions	p. 180
7.2.7 The Calibration of the Cutting Force Coefficients	p. 181
7.2.8 A Case Study: Verification	p. 186
7.3 A Dynamic Cutting Force Model for Ball-end Milling	p. 186
7.3.1 A Geometric Model of a Ball-end Mill	p. 186
7.3.2 Dynamic Cutting Force Modelling	p. 188
7.3.3 The Experimental Calibration of the Cutting Force Coefficients	p. 194
7.3.4 A Case Study: Verification	p. 198
7.4 A Machining Dynamics Model	p. 200
7.4.1 A Modularisation of the Cutting Force	p. 200
7.4.2 Machining Dynamics Modelling	p. 203
7.4.3 The Surface Generation Model	p. 205
7.4.4 Simulation Model	p. 207
7.5 The Modal Analysis of the Machining System	p. 207
7.5.1 The Mathematical Principle of Experimental Modal Analysis	p. 208
7.5.2 A Case Study	p. 209
7.6 The Application of the Machining Dynamics Model	p. 213
7.6.1 The Machining Setup	p. 213
7.6.2 Case 1: Cut 13	p. 214
7.6.3 Case 2: Cut 14	p. 219
7.7 The System Identification of Machining Processes	p. 224
7.7.1 The System Identification	p. 225
7.7.2 The Machining System and the Machining Process	p. 226
7.7.3 A Case Study	p. 227
7.7.4 Summary	p. 231
References	p. 231
8 Machining Dynamics in Grinding Processes	p. 233
8.1 Introduction	p. 233
8.2 The Kinematics and the Mechanics of Grinding	p. 236
8.2.1 The Geometry of Undeformed Grinding Chips	p. 236
8.3 The Generation of the Workpiece Surface in Grinding	p. 242
8.4 The Kinematics of a Grinding Cycle	p. 248
8.5 Applications of Grinding Kinematics and Mechanics	p. 253
8.6 Summary	p. 259
References	p. 261
9 Materials-induced Vibration in Single Point Diamond Turning	p. 263
9.1 Introduction	p. 263
9.2 A Model-based Simulation of the Nano-surface Generation	p. 264
9.2.1 A Prediction of the Periodic Fluctuation of Micro-cutting Forces	p. 265
9.2.2 Characterization of the Dynamic Cutting System	p. 269
9.2.3 A Surface Topography Model for the Prediction of Nano-surface Generation	p. 271
9.2.4 Prediction of the Effect of Tool Interference	p. 275
9.2.5 Prediction of the Effect of Material Anisotropy	p. 277
9.3 Conclusions	p. 278
Acknowledgements	p. 279
References	p. 279
10 Design of Precision Machines	p. 283
10.1 Introduction	p. 283
10.2 Principles	p. 284
10.2.1 Machine Tool Constitutions	p. 284
10.2.2 Machine Tool Loops and the Dynamics of Machine Tools	p. 288
10.2.3 Stiffness, Mass and Damping	p. 290
10.3 Methodology	p. 293
10.3.1 Design Processes of the Precision Machine	p. 293
10.3.2 Modelling and Simulation	p. 295
10.4 Implementation	p. 298
10.4.1 Static Analysis	p. 298
10.4.2 Dynamic Analysis	p. 298
10.4.3 A General Modelling and Analysis Process Using FEA	p. 300
10.5 Applications	p. 303
10.5.1 Design Case Study 1: A Piezo-actuator Based Fast Tool Servo System	p. 303
10.5.2 Design Case Study 2: A 5-axis Micro-milling/grinding Machine Tool	p. 313
10.5.3 Design Case Study 3: A Precision Grinding Machine Tool	p. 317
Acknowledgements	p. 320
References	p. 320
Index	p. 323

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