Cheng Machining Dynamics

Fundamentals, Applications and Practices
1. Auflage 2008
ISBN: 978-1-84628-368-0
Verlag: Springer-Verlag
Format: PDF
Kopierschutz: Adobe DRM (»Systemvoraussetzungen)

E-Book, Englisch, 328 Seiten

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.

Autoren/Hrsg.

Cheng, Kai

Inhaltsverzeichnis

1;Preface;6
2;Contents;9
3;List of Contributors;16
4;1 Introduction;18
5;2 Basic Concepts and Theory;24
6;3 Dynamic Analysis and Control;38
7;4 Dynamics Diagnostics: Methods, Equipment and Analysis Tools;102
8;5 Tool Design, Tool Wear and Tool Life;133
9;6 Machining Dynamics in Turning Processes;166
10;7 Machining Dynamics in Milling Processes;182
11;8 Machining Dynamics in Grinding Processes;247
12;9 Materials-induced Vibration in Single Point Diamond Turning;277
13;10 Design of Precision Machines;297
14;Index;336

Leseproben

1.1 Scope of the Subject

Machining processes are industrial processes in which typically metal parts are shaped by removal of unwanted materials. They are still the fundamental manufacturing techniques and it is expected to remain so for the next few decades. According to the International Institution of Production Research (CIRP), machining accounts for approximately half of all manufacturing techniques, which is a reflection of the achieved accuracy, productivity, reliability and energy consumption of this technique.

Future machine tools have to be highly dynamic systems to sustain the required productivity, accuracy and reliability. Both the machine tool system (Machine/ Tool-holder/Tool/Workpiece/Fixture) and machining processes are necessary to be optimized for their usability, cutting performance or the process capability to meet the productivity, precision and availability requirements of the end user. Furthermore, the machine dynamics and machining process dynamics are two indispensably integrated parts which should be taken into account simultaneously in optimizing the machine system, as illustrated in Figure 1.1.

The machining and machine dynamics within the machine system should be well understood, optimized and controlled, because they have the following direct effects:

• They may degrade machining accuracy and the machined surface texture and integrity.

• They may lead to chatter and unstable cutting conditions.

• They may cause accelerated tool wear and breakage.

• They may result in accelerated machine tool wear and damage to the machine and part.

• They may create unpleasant noises and sounds on the shopfloor because of the chatter and vibrations.

A number of analytical and experimental methods have been developed to study the dynamics of the machining system, with the two basic objectives [1, 2]:

(1) to identify rules and guidelines to design stable and robust machine tools, and

(2) to develop rules, models and algorithms for undertaking dynamically stable machining processes in an optimal and adaptive manner.

Machining dynamics are a major factor affecting many production operations, especially high speed machining. Taking account of machining dynamics is particularly important in fine finishing operations, such as grinding, diamond turning, and increasingly, nano/micro machining. As a subject, it is multidisciplinary covering cutting mechanics, tribology, sensor and instrumentation, machine design, tooling, process optimization and control, and manufacturing metrology. The subject combines anayltical and experimental work seamlessly together.

1.2 Scientific and Technological Challenges and Needs

The achievable quality of the precision machined surfaces is affected by four main issues as shown in Figure 1.2. They are the machining process, machine tool performance, workpiece material property and tooling geometry. A scientific approach is needed for building up a theoretical basis to bridge the gap between the surface machined and the determining factors from these four main issues, and to further explore that basis with respect to the desired surface integrity and intended functional performance through machining. It would therefore be of great significance to investigate the fundamentals of high precision surface generation from the manufacturing science viewpoint, which is essential for achieving high precision manufacturing with repeatability, predictability, producibility and productivity.