Machine Tool Structures, Volume 1 deals with fundamental theories and calculation methods for machine tool structures. Experimental investigations into stiffness are discussed, along with the application of the results to the design of machine tool structures. Topics covered range from static and dynamic stiffness to chatter in metal cutting, stability in machine tools, and deformations of machine tool structures. This volume is divided into three sections and opens with a discussion on stiffness specifications and the effect of stiffness on the behavior of the machine under forced vibration conditions. The following chapters explore the stability of the machine structure against chatter; methods of stability analysis; tests and principles of dampers; chatter during grinding operations; and stresses and deformations of closed box structures subjected to bending and shear. Calculation methods for determining stiffness constants of a structure's individual parts, as well as methods for determining the resulting stiffnesses, modal shapes, and their parameters, are also described. The final chapter presents systematic procedures for the analysis of machine tool structures. This book is intended for university students, research workers, and designers.

Machine tools are the main production factor for many industrial applications in many important sectors. 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 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. “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.

Metal cutting is widely used in producing manufactured products. The technology has advanced considerably along with new materials, computers and sensors. This new edition considers the scientific principles of metal cutting and their practical application to manufacturing problems. It begins with metal cutting mechanics, principles of vibration and experimental modal analysis applied to solving shop floor problems. There is in-depth coverage of chatter vibrations, a problem experienced daily by manufacturing engineers. Programming, design and automation of CNC (computer numerical control) machine tools, NC (numerical control) programming and CAD/CAM technology are discussed. The text also covers the selection of drive actuators, feedback sensors, modelling and control of feed drives, the design of real time trajectory generation and interpolation algorithms and CNC-oriented error analysis in detail. Each chapter includes examples drawn from industry, design projects and homework problems. This is ideal for advanced undergraduate and graduate students and also practising engineers.

This open access book summarizes the results of the European research project “Twin-model based virtual manufacturing for machine tool-process simulation and control” (Twin-Control). The first part reviews the applications of ICTs in machine tools and manufacturing, from a scientific and industrial point of view, and introduces the Twin-Control approach, while Part 2 discusses the development of a digital twin of machine tools. The third part addresses the monitoring and data management infrastructure of machines and manufacturing processes and numerous applications of energy monitoring. Part 4 then highlights various features developed in the project by combining the developments covered in Parts 3 and 4 to control the manufacturing processes applying the so-called CPSs. Lastly, Part 5 presents a complete validation of Twin-Control features in two key industrial sectors: aerospace and automotive. The book offers a representative overview of the latest trends in the manufacturing industry, with a focus on machine tools.

Design Principles of Metal-Cutting Machine Tools discusses the fundamentals aspects of machine tool design. The book covers the design consideration of metal-cutting machine, such as static and dynamic stiffness, operational speeds, gearboxes, manual, and automatic control. The text first details the data calculation and the general requirements of the machine tool. Next, the book discusses the design principles, which include stiffness and rigidity of the separate constructional elements and their combined behavior under load, as well as electrical, mechanical, and hydraulic drives for the operational movements. The next section deals with automatic control, including its principles, constructional elements, and applications. The last section tackles the design of constructional elements, such as machine tool structures, spindles and spindle bearings, and control and operating devices. The book will be of great use to mechanical and manufacturing engineers. Individuals involved in materials manufacturing industry will also benefit from the book.

This contributed volume collects the scientific results of the DFG Priority Program 1180 Prediction and Manipulation of the Interactions between Structures and Processes. The research program has been conducted during the years 2005 and 2011, whereas the primary goal was the analysis of the interactions between processes and structures in modern production facilities. This book presents the findings of the 20 interdisciplinary subprojects, focusing on different manufacturing processes such as high performance milling, tool grinding or metal forming. It contains experimental investigations as well as mathematical modeling of production processes and machine interactions. New experimental advancements and novel simulation approaches are also included.

A Complete Reference Covering the Latest Technology in Metal Cutting Tools, Processes, and Equipment Metal Cutting Theory and Practice, Third Edition shapes the future of material removal in new and lasting ways. Centered on metallic work materials and traditional chip-forming cutting methods, the book provides a physical understanding of conventional and high-speed machining processes applied to metallic work pieces, and serves as a basis for effective process design and troubleshooting. This latest edition of a well-known reference highlights recent developments, covers the latest research results, and reflects current areas of emphasis in industrial practice. Based on the authors’ extensive automotive production experience, it covers several structural changes, and includes an extensive review of computer aided engineering (CAE) methods for process analysis and design. Providing updated material throughout, it offers insight and understanding to engineers looking to design, operate, troubleshoot, and improve high quality, cost effective metal cutting operations. The book contains extensive up-to-date references to both scientific and trade literature, and provides a description of error mapping and compensation strategies for CNC machines based on recently issued international standards, and includes chapters on cutting fluids and gear machining. The authors also offer updated information on tooling grades and practices for machining compacted graphite iron, nickel alloys, and other hard-to-machine materials, as well as a full description of minimum quantity lubrication systems, tooling, and processing practices. In addition, updated topics include machine tool types and structures, cutting tool materials and coatings, cutting mechanics and temperatures, process simulation and analysis, and tool wear from both chemical and mechanical viewpoints. Comprised of 17 chapters, this detailed study: Describes the common machining operations used to produce specific shapes or surface characteristics Contains conventional and advanced cutting tool technologies Explains the properties and characteristics of tools which influence tool design or selection Clarifies the physical mechanisms which lead to tool failure and identifies general strategies for reducing failure rates and increasing tool life Includes common machinability criteria, tests, and indices Breaks down the economics of machining operations Offers an overview of the engineering aspects of MQL machining Summarizes gear machining and finishing methods for common gear types, and more Metal Cutting Theory and Practice, Third Edition emphasizes the physical understanding and analysis for robust process design, troubleshooting, and improvement, and aids manufacturing engineering professionals, and engineering students in manufacturing engineering and machining processes programs.