Machine Tools for High Performance Machining - Norberto Lopez de Lacalle

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Machine Tools for High Performance Machining

By: Norberto Lopez de Lacalle (Editor), Aitzol Lamikiz Mentxaka (Editor)

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Hardcover | 22 October 2008

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Hardcover
468 Pages

Dimensions(cm)
22.86 x 15.24 x 2.54

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Machine tools are the main production factor for many industrial applications, in important sectors such as the automotive and aeronautical industry, precision parts, human implants, and mechanical construction. Recent developments in new motion devices and numerical control have lead to considerable technological improvements in machine tools. The use of five-axis machining centres has also spread, resulting in reductions in set-up and lead times. As a consequence, feed rates, cutting speed and chip section increased, whilst accuracy and precision have improved as well. Additionally, new cutting tools have been developed, combining tough substrates, optimal geometries and wear resistant coatings. Today's machines and machining processes are clearly very different to those of the past.

Machine Tools for High Performance Machining describes in depth several aspects of machine structures, machine elements and control, and application. The basics, models and functions of each aspect are explained by experts from both academia and industry. Postgraduates, researchers and end users will all find this book an essential reference.

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You Can Find This Book In

Non-Fiction Engineering & Technology Industrial Chemistry & Manufacturing Technologies Mechanical Engineering & Materials Mechanical Engineering Technology in General Engineering in General Electronics & Communications Engineering Electronics Engineering Automatic Control Engineering Robotics Production & Industrial Engineering

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Paperback

Published: 13th October 2010

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Contributors	p. xix
Machine Tools for Removal Processes: A General View	p. 1
Basic Definitions and History	p. 1
Historical Remarks	p. 2
The Functions and Requirements of a Machine Tool	p. 8
User and Technological Requirements	p. 9
The Basic Mechanism	p. 13
The Machine Structure	p. 16
Machine Foundations	p. 18
Structural Components Materials	p. 18
Structural Analysis	p. 19
Modularity	p. 22
Guideways	p. 23
Guides with Limit Lubrication	p. 25
Rolling Guides	p. 25
Hydrostatic Guides	p. 26
The Definition of the Main Motion	p. 27
The Definition of the Drive Trains	p. 29
The CNC Implementation	p. 30
Machine Verification	p. 33
Typical Machines for Several Applications and Sectors	p. 34
A Machine for Big Structural Turbine Parts	p. 34
A Horizontal Milling Centre for Automotive Components	p. 35
A Milling Centre for Moulds	p. 37
A Milling Machine for Big Dies and Moulds	p. 37
Conventional Machines for Auxiliary Operations	p. 38
CNC Milling Machines for General Production	p. 40
A Heavy-duty Lathe	p. 40
A Mitre Band Saw	p. 41
Transfer Machines	p. 42
A Milling and Boring Centre	p. 43
The Book Organisation	p. 43
References	p. 44
New Concepts for Structural Components	p. 47
Introduction and Definitions	p. 47
Optimised Machine Structures	p. 49
A Comparison Among Different Machine Configurations	p. 50
Structural Components in Machine Structures	p. 53
Robust Rams and Columns	p. 54
Structural Optimisation in Machines	p. 56
Mechanical Requirements for Eco-efficient Machines	p. 56
FEM Modelling	p. 58
Topological Optimisation	p. 60
Structural Materials	p. 61
Involved Parameters	p. 61
Conventional Materials for Structural Components	p. 62
Innovative Materials for Structural Components	p. 63
Costs of Design Materials and Structures	p. 65
The Influence of Innovative Materials on Productivity	p. 65
Active Damping Devices	p. 66
The Implementation of ADDs to Machine Structures	p. 67
The Influence of New Structural Concepts on Productivity	p. 68
The Influence of New Design Concepts for Structural Components	p. 68
The Influence of ADDs on Productivity	p. 71
Future Trends in Structural Components for Machines	p. 72
References	p. 72
Machine Tool Spindles	p. 75
Introduction	p. 75
Types of Spindles	p. 78
Belt-driven Spindles	p. 78
Gear-driven Spindles	p. 79
Direct Drive Spindles	p. 79
Integrated (Built-in) Drive Spindles	p. 80
Spindle Configurations	p. 80
Common Configurations: Vertical and Horizontal Spindles	p. 81
Machines with Rotary Headstocks	p. 81
A Main Spindle with an Auxiliary Spindle	p. 82
Twin Spindles and Multi-spindles	p. 83
Automatic Head Exchange	p. 83
Basic Elements of the Spindle	p. 84
Motors	p. 85
Bearings	p. 87
The Toolholder	p. 95
The Drawbar	p. 102
The Shaft	p. 103
The Sensors	p. 103
The Housing	p. 104
Spindle Properties and Performance	p. 105
Spindle Power and Torque versus Spindle Speed Curves	p. 105
The Stiffness	p. 106
Dynamic Behaviour and Vibrations	p. 108
The Thermal Behaviour	p. 115
Spindles in Use: Other Problems	p. 119
Spindle Selection	p. 120
Conventional Machining or HSM	p. 121
Tool Selection	p. 122
The Workpiece Material	p. 123
Power and Spindle Speed Requirements	p. 123
Brief Conclusions	p. 125
References	p. 126
New Developments in Drives and Tables	p. 129
Introduction	p. 129
Precision and Dynamics	p. 130
Linear Drives by Ball Screws	p. 132
Dimensioning	p. 132
The Rotary Screw	p. 138
Other Configurations	p. 138
Linear Drives by Rack and Pinion	p. 139
The Elimination of the Gap	p. 139
Dimensioning	p. 141
Dynamic Models of the Drives	p. 142
Linear Drives by Linear Motors	p. 142
Mounting	p. 144
Configurations	p. 144
Rotary Drives	p. 145
Mechanical Transmissions	p. 145
Direct Rotary Drives	p. 146
Guidance Systems	p. 147
Friction Guides	p. 147
Rolling Guides	p. 150
Hydrostatic Guides	p. 152
Aerostatic Guides	p. 156
The Present and the Future	p. 157
Rolling Guides with Integrated Functions	p. 157
The Hydrostatic Shoe on Guide Rails	p. 157
Guiding and Actuation through Magnetic Levitation	p. 158
References	p. 158
Advanced Controls for New Machining Processes	p. 159
Introduction and History	p. 159
Computer Numerical Control and Direct Numerical Control	p. 160
Networked Control and Supervision	p. 163
New Machining Processes	p. 164
High Speed Machining	p. 165
Micromechanical Machining	p. 166
An Introduction to Nanomachining Processes	p. 167
Today's CNCs: Machine Level Control	p. 168
The Interpolation Process	p. 169
The Position Control Servomechanism	p. 174
Advanced CNCs: Multi-level Hierarchical Control	p. 179
The Control of the Machining Process	p. 181
The Supervisory Control of the Machining Process: Merit Variables	p. 183
The Sensory System for Machining Processes	p. 185
Correct Monitoring Conditions	p. 188
Machining Characteristics and their Measurement	p. 189
Two Case Studies	p. 190
Open-Architecture CNC Systems	p. 194
Networked Control and Supervision	p. 195
Programming Support Systems: Manual Programming	p. 202
Computer Assisted Programming	p. 207
Graphical Simulation	p. 209
Current CNC Architectures	p. 210
Systems Based on Multi-microprocessor Architecture	p. 211
The PC Front-end	p. 211
The Motion Control Card with a PC	p. 212
The Software-based Solution	p. 212
Fully Digital Architectures: Towards the Intelligent Machine Tool	p. 214
References	p. 216
Machine Tool Performance and Precision	p. 219
Introduction and Definitions	p. 220
An Introduction to Precision Machining	p. 220
Basic Definitions: Accuracy, Repeatability and Resolution	p. 223
Historical Remarks and the State of the Art	p. 224
Basic Design Principles and an Error Budget	p. 225
Sources of Errors in Machine Tools	p. 226
Error Budget Estimation	p. 227
Basic Principles for Precision Machine Design	p. 231
Error Propagation	p. 237
Thermal Errors	p. 240
CNC Interpolation Errors	p. 244
Errors Originated by the Machining Process	p. 245
Errors Originated in the CNC Program Generation	p. 245
Errors Originated by the Tool Wear	p. 247
Tool Deflection Error	p. 248
Verification Procedures	p. 251
Standard Procedures for Machine Tool Validation	p. 252
Test Parts	p. 257
A Brief Conclusion	p. 258
References	p. 259
New Developments in Lathes and Turning Centres	p. 261
Introduction	p. 261
Machine Configuration	p. 262
High Production Lathes	p. 262
Turning Centres: Multi-tasking Machines	p. 265
The Latest Technologies Applied to Lathes and Turning Centres	p. 270
General Configuration Technologies	p. 270
Complementary Technologies to Improve Machine Performance	p. 271
Special Machining Processes Applied in Multi-tasking Machines	p. 272
The Laser Application	p. 272
Roller Burnishing and Deep Rolling	p. 273
Ultrasonic Assisted Turning	p. 275
Cryogenic Gas Assisted Turning	p. 276
High-pressure Coolant Assisted Machining	p. 277
References	p. 278
High Performance Grinding Machines	p. 279
Introduction	p. 279
The Machine Configuration	p. 280
The Machine Architecture	p. 281
Materials Applied in Structural Parts	p. 286
Main Components	p. 288
Wheel Dressing Systems	p. 291
Process Lubrication and Cooling	p. 296
Integrated Measuring Devices	p. 297
Special Grinding Processes	p. 299
Peel Grinding Quick Point	p. 299
Speed Stroke Grinding	p. 300
Creep Feed Grinding	p. 301
High Efficiency Deep Grinding	p. 302
Machine and Process Monitoring and Control	p. 302
Monitored Parameters and Applied Sensors	p. 303
Control Strategies	p. 304
References	p. 305
Wire Electrical Discharge Machines	p. 307
Introduction	p. 307
The WEDM Process	p. 310
Accuracy and Speed	p. 312
WEDM Machines	p. 315
Wire Transport and Wire Thread Devices	p. 318
Machine Automation	p. 319
Workpiece Fixturing Systems	p. 321
Filtering Systems	p. 322
Wires for WEDM	p. 323
The Wire EDM of Advanced Materials	p. 326
Aeronautical Alloys	p. 326
Tungsten Carbide	p. 327
Advanced Ceramics and PCD	p. 328
Thin-wire EDM	p. 330
References	p. 332
Parallel Kinematics for Machine Tools	p. 335
Introduction	p. 335
Main Characteristics of the Parallel Kinematic Machines	p. 337
A Classification of the Parallel Kinematic Machines	p. 338
A Design Methodology for Parallel Kinematic Machines	p. 339
The Motion Pattern	p. 340
The Type Synthesis	p. 341
The Position Analysis	p. 345
Velocity Analysis, Singularities and Dynamics	p. 347
The Optimisation	p. 349
The Kinematic Calibration of PKMs	p. 349
A Mathematical Approach	p. 351
Measuring on External Methods	p. 353
Self-calibration Strategies	p. 358
The Control of Parallel Kinematic Machines	p. 358
Models Specific to Parallel Kinematics Machines	p. 360
The Dynamic Controller	p. 361
The Model-based Predictive Controller	p. 363
Conclusions and Future Trends	p. 365
References	p. 366
Micromilling Machines	p. 369
Introduction and Definitions	p. 369
The Micromilling Process	p. 371
Micromilling Tools	p. 372
Applications	p. 374
Miniaturised Machine Tools	p. 376
Machine Drives	p. 377
Conventional Ball Screw Configuration	p. 377
Friction Drives	p. 379
The Linear Motor	p. 380
New Tendencies: Hydrostatic Screws	p. 382
Guideways	p. 383
Special Rolling Guides Configurations	p. 383
Aerostatic and Hydrostatic Guides	p. 384
New Tendencies: Magnetic and Flexure Guidance Systems	p. 386
The High Speed Spindle and Collet	p. 389
Alternatives: Hydrostatic and Magnetic Spindles	p. 390
Measuring Systems	p. 392
Examples	p. 393
The Kern® Pyramid Nano	p. 393
The Kugler® Microgantry nano 3/5X	p. 395
References	p. 396
Machines for the Aeronautical Industry	p. 399
Aeronautical Business	p. 399
Aerospace Components	p. 400
Aerospace Structures	p. 401
Aerospace Engines	p. 402
Accessories	p. 403
Aerospace Materials	p. 403
Costs, Weight and Precision in Machine Tools for Aerospace Machining	p. 405
The Drive to Reduce Aircraft Costs	p. 406
The Drive to Reduce Aircraft Weight	p. 407
The Drive for Aircraft Component Precision	p. 407
Machine Tools for Aeronautical Components	p. 408
Machine Tools for Machining Aeronautical Structures	p. 409
Machine Tools for Machining Engine Components	p. 413
Machine Tools for Machining Accessories and Structure Fittings	p. 417
References	p. 419
Machine Tools for the Automotive Industry	p. 421
World Trends in Automotive Production	p. 421
The Economic Impact of the Automotive Industry	p. 421
Machining Processes in Automotive Production	p. 422
Manufacturing System Architecture: High Volume Production Versus Flexibility	p. 423
Dedicated Machines	p. 424
Flexible Cells	p. 427
Hybrid Systems	p. 429
Technology Trends	p. 433
References	p. 435
Index	p. 437
Table of Contents provided by Publisher. All Rights Reserved.

Machine Tools for High Performance Machining

At a Glance

Hardcover

Shipping

How to return your order

Defective items

You Can Find This Book In

Other Editions and Formats

Paperback

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