制造自动化 金属切削力学.机床振动和CNC设计(第2版)(英文版)

CHAPTER ONE INTRODUCTION 1
CHAPTER TWO MECHANICS OF METAL CUTTING 4
2.1 Introduction 4
2.2 Mechanics of Orthogonal Cutting 4
2.3 Mechanistic Modeling of Cutting Forces 15
2.4 Theoretical Prediction of Shear Angle 18
2.5 Mechanics of Oblique Cutting 19
2.5.1 Oblique Cutting Geometry 19
2.5.2 Solution of Oblique Cutting Parameters 21
2.5.3 Prediction of Cutting Forces 25
2.6 Mechanics of Turning Processes 27
2.7 Mechanics of Milling Processes 35
2.7.1 Mechanics of Helical End Mills 41
2.8 Analytical Modeling of End Milling Forces 43
2.8.1 Mechanistic Identification of Cutting Constants in Milling 46
2.9 Mechanics of Drilling 47
2.10 Tool Wear and Tool Breakage.54
2.10.1 Tool Wear 56
2.10.2 Tool Breakage 61
2.11 Problems 62 CHAPTER THREE STRUCTURAL DYNAMICS OF MACHINES 66
3.1 Introduction 66
3.2 Machine Tool Structures66
3.3 Dimensional Form Errors in Machining 68
3.3.1 Form Errors in Cylindrical Turning 68
3.3.2 Boring Bar 70
3.3.3 Form Errors in End Milling 71
3.4 Structural Vibrations in Machining.74
3.4.1 Fundamentals of Free and Forced Vibrations 75
3.4.2 Oriented Frequency Response Function.82
3.4.3 Design and Measurement Coordinate Systems 833.4.4 Analytical Modal Analysis for Multi？Degree-of-Freedom Systems 85
3.4.5 Relative Frequency Response Function between Tool and Workpiece 90
3.5 Modal Testing of Machine Structures 92
3.5.1 Theory of Frequency Response Testing 92
3.5.2 Experimental Procedures in Modal Testing 97
3.6 Experimental Modal Analysis for Multi？Degree-of-Freedom Systems 98
3.7 Identification of Modal Parameters 109
3.7.1 Global Nonlinear Optimization of Modal Parameter Identification 113
3.8 Receptance Coupling of End Mills to Spindle-Tool Holder Assembly 115
3.8.1 Experimental Procedure 118
3.9 Problems 120 CHAPTER FOUR MACHINE TOOL VIBRATIONS 125
4.1 Introduction 125
4.2 Stability of Regenerative Chatter Vibrations in Orthogonal Cutting 126
4.2.1 Stability of Orthogonal Cutting.126
4.2.2 Dimensionless Analysis of Stability Lobes in Orthogonal Cutting132
4.2.3 Chatter Stability of Orthogonal Cutting with Process Damping 135
4.3 Chatter Stability of Turning Operations 139
4.4 Chatter Stability of Turning Systems with Process Damping 142
4.4.1 Metal Cutting Forces 144
4.4.2 Process Damping Gains Contributed by Flank Wear 145
4.4.3 Stability Analysis 147
4.5 Experimental Validation 148
4.6 Analytical Prediction of Chatter Vibrations in Milling 149
4.6.1 Dynamic Milling Model 149
4.6.2 Zero-Order Solution of Chatter Stability in Milling 154
4.6.3 Multi-Frequency Solution of Chatter Stability in Milling 160
4.7 Chatter Stability of Drilling Operations 172
4.7.1 Dynamic Drilling Force Model 173
4.8 Frequency Domain Solution of Drilling Stability 176
4.9 Semidiscrete Time Domain Solution of Chatter Stability 178
4.9.1 Orthogonal Cutting 178
4.9.2 Discrete Time Domain Stability Solution in Milling 182
4.10 Problems186 CHAPTER FIVE TECHNOLOGY OF MANUFACTURING AUTOMATION 191
5.1 Introduction 191 5.2 Computer Numerically Controlled Unit 191
5.2.1 Organization of a CNC Unit 191
5.2.2 CNC Executive.193
5.2.3 CNC Machine Tool Axis Conventions 193
5.2.4 NC Part Program Structure 193
5.2.5 Main Preparatory Functions 196
5.3 Computer-Assisted NC Part Programming 201
5.3.1 Basics of Analytical Geometry201
5.3.2 APT Part Programming Language 206
5.4 Trajectory Generation for Computer-Controlled Machines 211
5.4.1 Interpolation with Constant Displacement212
5.4.2 Acceleration-Limited Velocity Profile Generation with Constant Interpolation Period 216
5.4.3 Jerk-Limited Velocity Profile Generation 220
5.5 Real-Time Interpolation Methods 229
5.5.1 Linear Interpolation Algorithm 230
5.5.2 Circular Interpolation Algorithm 234
5.5.3 Quintic Spline Interpolation within CNC Systems 239
5.6 Problems 245 CHAPTER SIX DESIGN AND ANALYSIS OF CNC SYSTEMS 250
6.1 Introduction 250
6.2 Machine Tool Drives 250
6.2.1 Mechanical Components and Torque Requirements.251
6.2.2 Feedback Devices 256
6.2.3 Electrical Drives.257
6.2.4 Permanent Magnet Armature-Controlled dc Motors 258
6.2.5 Position Control Loop 263
6.3 Transfer Function of the Position Loop 264
6.4 State Space Model of Feed Drive Control Systems 268
6.5 Sliding Mode Controller 281
6.6 Active Damping of Feed Drives 285
6.7 Design of an Electrohydraulic CNC Press Brake 293
6.7.1 Hydraulic Press Brake System 293
6.7.2 Dynamic Model of Hydraulic Actuator Module 296
6.7.3 Identification of Electrohydraulic Drive Dynamics for Computer Control 299
6.7.4 Digital Position Control System Design 301
6.8 Problems 307 CHAPTER SEVEN SENSOR-ASSISTED MACHINING 313
7.1 Introduction 313
7.2 Intelligent Machining Module 313
7.2.1 Hardware Architecture 314
7.2.2 Software Architecture 315
7.2.3 Intelligent Machining Application 316
7.3 Adaptive Control of Peak Forces in Milling 317
7.3.1 Introduction 317
7.3.2 Discrete Transfer Function of the Milling Process System 319
7.3.3 Pole-Placement Control Algorithm 321
7.3.4 Adaptive Generalized Predictive Control of Milling Process 325
7.3.5 In-Process Detection of Tool Breakage 330
7.3.6 Chatter Detection and Suppression 333
7.4 Intelligent Pocketing with the IMM System 334
7.5 Problems 336 APPENDIX A LAPLACE AND z TRANSFORMS 341
PPENDIX B  OFF-LINE AND ON-LINE PARAMETER ESTIMATION WITH LEAST SQUARES 353
Bibliography 357
Index 363