Machine Tools for High Performance Machining




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 centers has also spread, resulting in reductions in set-up and lead times. As a consequence, feed rates, cutting speed and chip section have increased, while 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

1 Machine Tools for Removal Processes: A General View
1.1 Basic Definitions and History
1.1.1 Historical Remarks
1.2 The Functions and Requirements of a Machine Tool
1.2.1 User and Technological Requirements
1.3 The Basic Mechanism
1.4 The Machine Structure
1.4.1 Machine Foundations
1.4.2 Structural Components Materials
1.4.3 Structural Analysis
1.4.4 Modularity
1.5 Guideways
1.5.1 Guides with Limit Lubrication
1.5.2 Rolling Guides
1.5.3 Hydrostatic Guides
1.6 The Definition of the Main Motion
1.7 The Definition of the Drive Trains
1.8 The CNC Implementation
1.9 Machine Verification
1.10 Typical Machines for Several Applications and Sectors
1.10.1 A Machine for Big Structural Turbine Parts
1.10.2 A Horizontal Milling Centre for Automotive Components
1.10.3 A Milling Centre for Moulds
1.10.4 A Milling Machine for Big Dies and Moulds
1.10.5 Conventional Machines for Auxiliary Operations
1.10.6 CNC Milling Machines for General Production
1.10.7 A Heavy-duty Lathe
1.10.8 A Mitre Band Saw
1.10.9 Transfer Machines
1.10.10 A Milling and Boring Centre
1.11 The Book Organisation
2 New Concepts for Structural Components
2.1 Introduction and Definitions
2.2 Optimised Machine Structures
2.2.1 A Comparison Among Different Machine Configurations
2.2.2 Structural Components in Machine Structures
2.2.3 Robust Rams and Columns
2.3 Structural Optimisation in Machines
2.3.1 Mechanical Requirements for Eco-efficient Machines
2.3.2 FEM Modelling
2.3.3 Topological Optimisation
2.4 Structural Materials
2.4.1 Involved Parameters
2.4.2 Conventional Materials for Structural Components
2.4.3 Innovative Materials for Structural Components
2.4.4 Costs of Design Materials and Structures
2.4.5 The Influence of Innovative Materials on Productivity
2.5 Active Damping Devices
2.5.1 The Implementation of ADDs to Machine Structures
2.6 The Influence of New Structural Concepts on Productivity
2.6.1 The Influence of New Design Concepts
for Structural Components
2.6.2 The Influence of ADDs on Productivity
2.7 Future Trends in Structural Components for Machines
3 Machine Tool Spindles
3.1 Introduction
3.2 Types of Spindles
3.2.1 Belt-driven Spindles
3.2.2 Gear-driven Spindles
3.2.3 Direct Drive Spindles
3.2.4 Integrated (Built-in) Drive Spindles
3.3 Spindle Configurations
3.3.1 Common Configurations
Vertical and Horizontal Spindles
3.3.2 Machines with Rotary Headstocks
3.3.3 A Main Spindle with an Auxiliary Spindle
3.3.5 Automatic Head Exchange
Basic Elements of the Spindle
3.4.1 Motors
3.4.2 Bearings
3.4.3 The Toolholder
3.4.4 The Drawbar
3.4.5 The Shaft
3.4.6 The Sensors
3.4.7 The Housing
Spindle Properties and Performance
3.5.1 Spindle Power and Torque
versus Spindle Speed Curves
3.5.2 The Stiffness
3.5.3 Dynamic Behaviour and Vibrations
3.5.4 The Thermal Behaviour
3.5.5 Spindles in Use: Other Problems
Spindle Selection
3.6.1 Conventional Machining or HSM
3.6.2 Tool Selection
3.6.3 The Workpiece Material
3.6.4 Power and Spindle Speed Requirements
Brief Conclusions
4 New Developments in Drives and Tables
4.1 Introduction
4.1.1 Precision and Dynamics
4.2 Linear Drives by Ball Screws
4.2.1 Dimensioning
4.2.2 The Rotary Screw
4.2.3 Other Configurations
4.3 Linear Drives by Rack and Pinion
4.3.1 The Elimination of the Gap
4.3.2 Dimensioning
4.3.3 Dynamic Models of the Drives
4.4 Linear Drives by Linear Motors
4.4.1 Mounting
4.4.2 Configurations
4.5 Rotary Drives
4.5.1 Mechanical Transmissions
4.5.2 Direct Rotary Drives
4.6 Guidance Systems
4.6.1 Friction Guides
4.6.2 Rolling Guides
4.6.3 Hydrostatic Guides
4.6.4 Aerostatic Guides
4.7 The Present and the Future
4.7.1 Rolling Guides with Integrated Functions
4.7.2 The Hydrostatic Shoe on Guide Rails
4.7.3 Guiding and Actuation through Magnetic Levitation
5 Advanced Controls for New Machining Processes
5.1 Introduction and History
5.1.1 Computer Numerical Control
and Direct Numerical Control
5.1.2 Networked Control and Supervision
5.2 New Machining Processes
5.2.1 High Speed Machining
5.2.2 Micromechanical Machining
5.2.3 An Introduction to Nanomachining Processes
5.3 Today’s CNCs: Machine Level Control
5.3.1 The Interpolation Process
5.3.2 The Position Control Servomechanism
5.4 Advanced CNCs: Multi-level Hierarchical Control
5.4.1 The Control of the Machining Process
5.4.2 The Supervisory Control of the Machining Process: Merit Variables
5.5 The Sensory System for Machining Processes
5.5.1 Correct Monitoring Conditions
5.5.2 Machining Characteristics and their Measurement
5.5.3 Two Case Studies
5.6 Open-Architecture CNC Systems
5.6.1 Networked Control and Supervision
5.7 Programming Support Systems: Manual Programming
5.7.1 Computer Assisted Programming
5.7.2 Graphical Simulation
5.8 Current CNC Architectures
5.8.1 Systems Based on Multi-microprocessor Architecture
5.8.2 The PC Front-end
5.8.3 The Motion Control Card with a PC
5.8.4 The Software-based Solution
5.8.5 Fully Digital Architectures
Towards the Intelligent Machine Tool
6 Machine Tool Performance and Precision
6.1 Introduction and Definitions
6.1.1 An Introduction to Precision Machining
6.1.2 Basic Definitions
Accuracy, Repeatability and Resolution
6.1.3 Historical Remarks and the State of the Art
6.2 Basic Design Principles and an Error Budget
6.2.1 Sources of Errors in Machine Tools
6.2.2 Error Budget Estimation
6.2.3 Basic Principles for Precision Machine Design
6.2.4 Error Propagation
6.2.5 Thermal Errors
6.2.6 CNC Interpolation Errors
6.3 Errors Originated by the Machining Process
6.3.1 Errors Originated in the CNC Program Generation
6.3.2 Errors Originated by the Tool Wear
6.3.3 Tool Deflection Error
6.4 Verification Procedures
6.4.1 Standard Procedures for Machine Tool Validation
6.4.2 Test Parts
6.5 A Brief Conclusion
7 New Developments in Lathes and Turning Centres
7.1 Introduction
7.2 Machine Configuration
7.2.1 High Production Lathes
7.2.2 Turning Centres: Multi-tasking Machines
7.3 The Latest Technologies Applied to Lathes and Turning Centres
7.3.1 General Configuration Technologies
7.3.2 Complementary Technologies to Improve Machine Performance
7.4 Special Machining Processes Applied
in Multi-tasking Machines
7.4.1 The Laser Application
7.4.2 Roller Burnishing and Deep Rolling
7.4.3 Ultrasonic Assisted Turning
7.4.4 Cryogenic Gas Assisted Turning
7.4.5 High-pressure Coolant Assisted Machining
8 High Performance Grinding Machines
8.1 Introduction
8.2 The Machine Configuration
8.2.1 The Machine Architecture
8.2.2 Materials Applied in Structural Parts
8.2.3 Main Components
8.2.4 Wheel Dressing Systems
8.2.5 Process Lubrication and Cooling
8.2.6 Integrated Measuring Devices
8.3 Special Grinding Processes
8.3.1 Peel Grinding–Quick Point
8.3.2 Speed Stroke Grinding
8.3.3 Creep Feed Grinding
8.3.4 High Efficiency Deep Grinding
8.4 Machine and Process Monitoring and Control
8.4.1 Monitored Parameters and Applied Senso
8.4.2 Control Strategies
9 Wire Electrical Discharge Machines
9.1 Introduction
9.2 The WEDM Process
9.2.1 Accuracy and Speed
9.3 WEDM Machines
9.3.1 Wire Transport and Wire Thread
9.3.2 Machine Automation
9.3.3 Workpiece Fixturing Systems
9.3.4 Filtering Systems
9.4 Wires for WEDM
9.5 The Wire EDM of Advanced Materials
9.5.1 Aeronautical Alloys
9.5.2 Tungsten Carbide
9.5.3 Advanced Ceramics and PCD
9.6 Thin-wire EDM
10 Parallel Kinematics for Machine Tools
10.1 Introduction
10.2 Main Characteristics of the Parallel Kinematic Machines
10.3 A Classification of the Parallel Kinematic Machines
10.4 A Design Methodology for Parallel Kinematic Machines
10.4.1 The Motion Pattern
10.4.2 The Type Synthesis
10.4.3 The Position Analysis
10.4.4 Velocity Analysis, Singularities and Dynamics
10.4.5 The Optimisation
10.5 The Kinematic Calibration of PKMs
10.5.1 A Mathematical Approach
10.5.2 Measuring on External Methods
10.5.3 Self-calibration Strategies
10.6 The Control of Parallel Kinematic Machines
10.6.1 Models Specific to Parallel Kinematics Machines
10.6.2 The Dynamic Controller
10.6.3 The Model-based Predictive Controller
10.7 Conclusions and Future Trends
11 Micromilling Machines
11.1 Introduction and Definitions
11.2 The Micromilling Process
11.2.1 Micromilling Tools
11.2.2 Applications
11.3 Miniaturised Machine Tools
11.4 Machine Drives
11.4.1 Conventional Ball Screw Configuration
11.4.2 Friction Drives
11.4.3 The Linear Motor
11.4.4 New Tendencies: Hydrostatic Screws
11.5 Guideways
11.5.1 Special Rolling Guides Configurations
11.5.2 Aerostatic and Hydrostatic Guides
11.5.3 New Tendencies: Magnetic and Flexure Guidance Systems
11.6 The High Speed Spindle and Collet
11.6.1 Alternatives: Hydrostatic and Magnetic Spindles
11.7 Measuring Systems
11.8 Examples

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