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Machining Dynamics

Fundamentals, Applications and Practices

By: Kai Cheng (Editor)

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Hardcover | 25 November 2008

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348 Pages

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23.39 x 15.6 x 2.06

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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.

Industry Reviews

From the reviews:

[Machining Dynamics] can be used for final undergraduate engineering course (for example, manufacturing, mechanical, etc.) or as a subject on manufacturing at the postgraduate level. Also, this book can serve as a useful reference for academics, manufacturing researchers, mechanical and manufacturing engineers, professional in related industries with machine tools and machining processes.

Davim, J.P. (2009) 'Machining Dynamics by Kai Cheng (Ed.)', Int. J. Machining and Machinability of Materials.

"Machining dynamics is an important area for the advancement of national economies. ... This book is the work of 16 authors. ... 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, Choice, Vol. 46 (9), May, 2009)

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Non-Fiction Engineering & Technology Industrial Chemistry & Manufacturing Technologies Technology in General Engineering in General Mechanical Engineering & Materials Mechanical Engineering Technical Design Production & Industrial Engineering

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Paperback

Published: 28th October 2010

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List of Contributors	p. xvii
Introduction	p. 1
Scope of the Subject	p. 1
Scientific and Technological Challenges and Needs	p. 2
Emerging Trends	p. 4
References	p. 6
Basic Concepts and Theory	p. 7
Introduction	p. 7
Loop Stiffness within the Machine-tool-workpiece System	p. 7
Machine-tool-workpiece Loop Concept	p. 7
Static Loop Stiffness	p. 8
Dynamic Loop Stiffness and Deformation	p. 9
Vibrations in the Machine-tool System	p. 10
Free Vibrations in the Machine-tool System	p. 10
Forced Vibrations	p. 13
Chatter Occurring in the Machine Tool System	p. 15
Definition	p. 15
Types of Chatters	p. 16
The Suppression of Chatters	p. 16
Machining Instability and Control	p. 17
The Conception of Machining Instability	p. 17
The Classification of Machining Instability	p. 19
Acknowledgements	p. 19
References	p. 19
Dynamic Analysis and Control	p. 21
Machine Tool Structural Deformations	p. 21
Machining Process Forces	p. 22
The Deformations of Machine Tool Structures and Workpieces	p. 30
The Control and Minimization of Form Errors	p. 39
Machine Tool Dynamics	p. 43
Experimental Methods	p. 43
The Analytical Modelling of Machine Tool Dynamics	p. 47
The Dynamic Cutting Process	p. 54
Mechanic of Dynamic Cutting	p. 55
The Dynamic Chip Thickness and Cutting Forces	p. 59
Stability of Cutting Process	p. 63
Stability of Turning	p. 64
The Stability of the Milling Process	p. 68
Maximizing Chatter Free Material Removal Rate in Milling	p. 74
Chatter Suppression-Variable Pitch End Mills	p. 79
Conclusions	p. 82
References	p. 83
Dynamics Diagnostics: Methods, Equipment and Analysis Tools	p. 85
Introduction	p. 85
Theory	p. 86
An Example	p. 88
The Substructure Analysis	p. 90
Experimental Equipment	p. 92
The Signal Processing	p. 92
Excitation Techniques	p. 93
The Measurement Equipment	p. 93
Novel Approaches	p. 94
In-process Sensors	p. 96
Dynamometers	p. 96
The Current Monitoring	p. 97
The Audio Measurement	p. 97
Capacitance Probes	p. 97
Telemetry and Slip Rings	p. 98
Fibre-optic Bragg Grating Sensors	p. 98
Chatter Detection Techniques	p. 98
The Topography	p. 100
The Frequency Domain	p. 100
Time Domain	p. 105
Wavelet Transforms	p. 109
Soft Computing	p. 110
The Information Theory	p. 111
Summary and Conclusions	p. 111
Acknowledgements	p. 112
References	p. 112
Tool Design, Tool Wear and Tool Life	p. 117
Tool Design	p. 118
The Tool-workpiece Replication Model	p. 118
Tool Design Principles	p. 120
The Tool Design for New Machining Technologies	p. 123
Tool Materials	p. 124
High Speed Steel	p. 124
Cemented Carbide	p. 124
Cermet	p. 125
Ceramics	p. 125
Diamond	p. 126
Cubic Boron Nitride	p. 127
High-performance Coated Tools	p. 127
Tool Coating Methods	p. 128
The Cutting Performance of PVD Coated Tools	p. 129
The Cutting Performance of CVD Coated Tools	p. 132
Recoating of Worn Tools	p. 133
Tool Wear	p. 133
Tool Wear Classification	p. 134
Tool Wear Evolution	p. 136
The Material-dependence of Wear	p. 138
The Wear of Diamond Tools	p. 139
Tool Life	p. 142
The Definition of Tool Life	p. 142
Taylor's Tool Life Model	p. 142
The Extended Taylor's Model	p. 144
Tool Life and Machining Dynamics	p. 145
References	p. 148
Machining Dynamics in Turning Processes	p. 151
Introduction	p. 151
Principles	p. 151
The Turning Process	p. 153
Methodology and Tools for the Dynamic Analysis and Control	p. 154
Implementation Perspectives	p. 155
Applications	p. 156
The Rigidity of the Machine Tool, the Tool Fixture and the Work Material	p. 156
The Influence of the Input Parameters	p. 162
Conclusions	p. 164
References	p. 164
Machining Dynamics in Milling Processes	p. 167
Introduction	p. 167
Forced Vibration	p. 167
Self-excited Vibration	p. 168
The Scope of This Chapter	p. 169
Nomenclature in This Chapter	p. 170
The Dynamic Cutting Force Model for Peripheral Milling	p. 171
Oblique Cutting	p. 172
The Geometric Model of a Helical End Mill	p. 173
Differential Tangential and Normal Cutting Forces	p. 174
Undeformed Chip Thickness	p. 175
Differential Cutting Forces in X and Y Directions	p. 178
Total Cutting Forces in X and Y Directions	p. 180
The Calibration of the Cutting Force Coefficients	p. 181
A Case Study: Verification	p. 186
A Dynamic Cutting Force Model for Ball-end Milling	p. 186
A Geometric Model of a Ball-end Mill	p. 186
Dynamic Cutting Force Modelling	p. 188
The Experimental Calibration of the Cutting Force Coefficients	p. 194
A Case Study: Verification	p. 198
A Machining Dynamics Model	p. 200
A Modularisation of the Cutting Force	p. 200
Machining Dynamics Modelling	p. 203
The Surface Generation Model	p. 205
Simulation Model	p. 207
The Modal Analysis of the Machining System	p. 207
The Mathematical Principle of Experimental Modal Analysis	p. 208
A Case Study	p. 209
The Application of the Machining Dynamics Model	p. 213
The Machining Setup	p. 213
Case 1: Cut 13	p. 214
Case 2: Cut 14	p. 219
The System Identification of Machining Processes	p. 224
The System Identification	p. 225
The Machining System and the Machining Process	p. 226
A Case Study	p. 227
Summary	p. 231
References	p. 231
Machining Dynamics in Grinding Processes	p. 233
Introduction	p. 233
The Kinematics and the Mechanics of Grinding	p. 236
The Geometry of Undeformed Grinding Chips	p. 236
The Generation of the Workpiece Surface in Grinding	p. 242
The Kinematics of a Grinding Cycle	p. 248
Applications of Grinding Kinematics and Mechanics	p. 253
Summary	p. 259
References	p. 261
Materials-induced Vibration in Single Point Diamond Turning	p. 263
Introduction	p. 263
A Model-based Simulation of the Nano-surface Generation	p. 264
A Prediction of the Periodic Fluctuation of Micro-cutting Forces	p. 265
Characterization of the Dynamic Cutting System	p. 269
A Surface Topography Model for the Prediction of Nano-surface Generation	p. 271
Prediction of the Effect of Tool Interference	p. 275
Prediction of the Effect of Material Anisotropy	p. 277
Conclusions	p. 278
Acknowledgements	p. 279
References	p. 279
Design of Precision Machines	p. 283
Introduction	p. 283
Principles	p. 284
Machine Tool Constitutions	p. 284
Machine Tool Loops and the Dynamics of Machine Tools	p. 288
Stiffness, Mass and Damping	p. 290
Methodology	p. 293
Design Processes of the Precision Machine	p. 293
Modelling and Simulation	p. 295
Implementation	p. 298
Static Analysis	p. 298
Dynamic Analysis	p. 298
A General Modelling and Analysis Process Using FEA	p. 300
Applications	p. 303
Design Case Study 1: A Piezo-actuator Based Fast Tool Servo System	p. 303
Design Case Study 2: A 5-axis Micro-milling/grinding Machine Tool	p. 313
Design Case Study 3: A Precision Grinding Machine Tool	p. 317
Acknowledgements	p. 320
References	p. 320
Index	p. 323
Table of Contents provided by Ingram. All Rights Reserved.

Machining Dynamics

Fundamentals, Applications and Practices

At a Glance

Hardcover

Industry Reviews

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