Machining Dynamics: Fundamentals, Applications and Practices

340 Pages·2009·9.579 MB·English

by  Kai Cheng (auth.), Kai Cheng (eds.)

Springer Series in Advanced Manufacturing
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Kai Cheng
Editor
Machining Dynamics
Fundamentals, Applications and Practices

123
Kai Cheng, BEng, MSc, PhD, FIET, MIMechE
Advanced Manufacturing & Enterprise
Engineering (AMEE) Department
School of Engineering and Design
Brunel University
Middlesex UB8 3PH
UK

ISBN 978-1-84628-367-3 e-ISBN 978-1-84628-368-0
DOI 10.1007/978-1-84628-368-0
Springer Series in Advanced Manufacturing ISSN 1860-5168
British Library Cataloguing in Publication Data
Machining dynamics : fundamentals, applications and
practices. - (Springer series in advanced manufacturing)
1. Machine-tools - Dynamics 2. Machining
I. Cheng, Kai
621.9'02
ISBN-13: 9781846283673
Library of Congress Control Number: 2008923551
© 2009 Springer-Verlag London Limited
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Preface
Machining dynamics plays an essential role in the performance of machine tools
and machining processes, which directly affects the material removal rate, and
workpiece surface quality as well as dimensional and form accuracy. However,
despite its obvious technical and economic importance and tremendous progress in
machining technology during the last few decades, machining dynamics still
remains as one of the least understood manufacturing science topics. In industrial
practices, machining parameters are still chosen primarily through empirical testing
and the experience of machine operators and programmers. This approach is
costly, and while databases have been developed from large numbers of empirical
tests, these databases lose relevance as new tools, machines and workpiece
materials are developed and applied. Furthermore, a better understanding of
machining dynamics is becoming increasingly important for engaging in
ultraprecision and micro manufacturing because of the machining accuracy, scale
and complexity involved. Therefore, it is essential to systematically research the
machining dynamics within the material removal and surface generation processes
and machine operations with particular respect to the quantitative effects from
machine tools, tooling, process variables and workpiece materials.

The advances in computational modelling, sensors, diagnostic equipment and
analysis tools, surface metrology, and manufacturing science during the past
decade have enabled academia and engineers to research the machining dynamics
from a new dimension and therefore to have the potential for great industrial
benefits, for instance, including:
• Analysis of the material removal dynamics, particularly the effects of
cutting speeds and tooling geometry on the stress and temperature
conditions at the tool-workpiece interface and thus the surface integrity and
functionality.
• Multi-body dynamic analysis of the machine tool structure including the
dynamic properties of interfaces between components such as spindles,
slideways and drive systems, etc.
vi Preface
• Design of machine tool structures for dynamic repeatability, which is
important in predictive control of the machine dynamic performance.
• Dynamic modelling of the machine systems (machine and machining
processes) and on line/real time identification of the system modal
parameters.
• Development of analytical solutions for the stability of complex contours
machining and nonlinear models of interrupted machining.
• Development of novel algorithms (integrated with existing
CAD/CAM/CAE tools) for compensation control of machining errors at
real time.
• Ultraprecision and micromachining of various engineering materials with
predictability, producibility and productivity.
• Modelling, simulation, control and optimization of precision machined
surfaces including their surface texture, topography, integrity and
functionality generation and formation.
This book aims to provide the state of the art of research and engineering
practice in machining dynamics which is becoming increasingly important in
modern manufacturing engineering. The book is concerned with machining
dynamics in a comprehensive systematic manner and utilizing it proactively in
manufacturing practice.

The advances in precision/ultraprecision machining, high speed machining, micro
manufacturing, and computational modelling and analysis tools that have led to
machining dynamics in the new context are the subject of the first chapter. The
machine-tool-workpiece loop stiffness can place deterministic effects on the
machining system’s performance. Scientific understanding and comprehension of
fundamentals of the loop and its dynamic behaviour in the process is central to the
progress of this technology. Basic concepts and theory of machining instability and
dynamics associated with the loop are therefore formulated in Chapter 2. Further
advancements in the technology can be aided through a generalized theoretical
understanding, scientific diagnostics and experimental analysis of machining
dynamics as presented in Chapters 3 and 4. Following up those, a series of
investigations are discussed on dynamics in tooling design, various machining
processes, and design of precision machines. First, tooling design, tool wear and
tool life are presented in Chapter 5. Machining dynamics in turning, milling and
grinding processes are then studied in Chapters 6, 7 and 8, respectively. With the
inexorable transition from conventional and precision machining, to ultraprecision
and micro/nano machining, micro machining dynamics are starting to attract
attention. Chapter 9 is devoted to the dynamics in ultraprecision machining using a
single point diamond tool and the associated impact on nano-surface generation.
Chapter 10 provides a dynamics-driven approach to precision machines design and
thorough discussions on its implementation and application perspectives.

Owing to the diverse character of the subject, a single notation for the book has
been difficult to achieve. For ease of working, therefore, a list of principal symbols
and their meanings is included in the appropriate chapters as needed.
Preface vii
The diversity of the subject of machining dynamics has required that specialists in
each of its main fields should prepare the chapters of this book. The comprehensive
interest in the subject is evident, with 16 authors coming from 12 academic and
industrial institutions. I am grateful to them all, for the benefit of their advice and
expertise, and their patience in supplying with me their specialist chapters, and in
many cases for lengthy subsequent dialogues.

This book can be used as a textbook for a final year elective subject on
manufacturing engineering, or as an introductory subject on machining technology
at the postgraduate level. It can also be used as a textbook for teaching advanced
manufacturing technology in general. The book can also serve as a useful reference
for manufacturing engineers, production supervisors, and planning and application
engineers, as well as industrial engineers.

At Brunel University, I am indebted to my colleagues Dr Dehong Huo, Ms Sara
Sun, Khalid Nor, Lei Zhou and Dr Rhys Morgan for their assistance in checking
many of the details of the chapters. At the publisher, Springer-Verlag London Ltd,
I have been appreciative of the support from Simon Rees, Anthony Doyle, Cornelia
Kresser and Nicolas Wilson, as the book has developed from its draft outline form
through various stages of its production.

Finally and most importantly, my greatest thanks have to be reserved for my wife,
Lucy Lu, and Mike Cheng for their steadfast support and interest throughout the
preparation of the book.

Brunel University Kai Cheng
West London, UK
Contents
List of Contributors............................................................................................xvii

1 Introduction.........................................................................................................1
1.1 Scope of the Subject.......................................................................................1
1.2 Scientific and Technological Challenges and Needs......................................2
1.3 Emerging Trends............................................................................................4
References............................................................................................................6
2 Basic Concepts and Theory................................................................................7
2.1 Introduction....................................................................................................7
2.2 Loop Stiffness within the Machine-tool-workpiece System...........................7
2.2.1 Machine-tool-workpiece Loop Concept.................................................7
2.2.2 Static Loop Stiffness..............................................................................8
2.2.3 Dynamic Loop Stiffness and Deformation.............................................9
2.3 Vibrations in the Machine-tool System........................................................10
2.3.1 Free Vibrations in the Machine-tool System........................................10
2.3.2 Forced Vibrations.................................................................................13
2.4 Chatter Occurring in the Machine Tool System...........................................15
2.4.1 Definition.............................................................................................15
2.4.2 Types of Chatters................................................................................16
2.4.3 The Suppression of Chatters................................................................16
2.5 Machining Instability and Control................................................................17
2.5.1 The Conception of Machining Instability............................................17
x Contents
2.5.2 The Classification of Machining Instability.........................................19
Acknowledgements............................................................................................19
References..........................................................................................................19
3 Dynamic Analysis and Control..........................................................................21
3.1 Machine Tool Structural Deformations........................................................21
3.1.1 Machining Process Forces...................................................................22
3.1.2 The Deformations of Machine Tool Structures and Workpieces.........30
3.1.3 The Control and Minimization of Form Errors....................................39
3.2. Machine Tool Dynamics.............................................................................43
3.2.1 Experimental Methods.........................................................................43
3.2.2 The Analytical Modelling of Machine Tool Dynamics.......................47
3.3. The Dynamic Cutting Process.....................................................................54
3.3.1. Mechanic of Dynamic Cutting............................................................55
3.3.2. The Dynamic Chip Thickness and Cutting Forces..............................59
3.4. Stability of Cutting Process.........................................................................63
3.4.1 Stability of Turning..............................................................................64
3.4.2. The Stability of the Milling Process....................................................68
3.4.3. Maximizing Chatter Free Material Removal Rate in Milling.............74
3.4.4. Chatter Suppression-Variable Pitch End Mills...................................79
3.5. Conclusions.................................................................................................82
References..........................................................................................................83
4 Dynamics Diagnostics: Methods, Equipment and Analysis Tools.................85
4.1 Introduction..................................................................................................85
4.2 Theory..........................................................................................................86
4.2.1 An Example.........................................................................................88
4.2.2 The Substructure Analysis...................................................................90
4.3 Experimental Equipment..............................................................................92
4.3.1 The Signal Processing..........................................................................92
4.3.2 Excitation Techniques..........................................................................93
4.3.3 The Measurement Equipment..............................................................93
4.3.4 Novel Approaches................................................................................94
4.3.5 In-process Sensors...............................................................................96
Contents xi
4.3.6 Dynamometers.....................................................................................96
4.3.7 The Current Monitoring.......................................................................97
4.3.8 The Audio Measurement......................................................................97
4.3.9 Capacitance Probes..............................................................................97
4.3.10 Telemetry and Slip Rings...................................................................98
4.3.11 Fibre-optic Bragg Grating Sensors.....................................................98
4.4 Chatter Detection Techniques......................................................................98
4.4.1 The Topography.................................................................................100
4.4.2 The Frequency Domain......................................................................100
4.4.3 Time Domain.....................................................................................105
4.4.4 Wavelet Transforms...........................................................................109
4.4.5 Soft Computing..................................................................................110
4.4.6 The Information Theory.....................................................................111
4.5 Summary and Conclusions.........................................................................111
Acknowledgements..........................................................................................112
References........................................................................................................112
5 Tool Design, Tool Wear and Tool Life..........................................................117
5.1 Tool Design................................................................................................118
5.1.1 The Tool-workpiece Replication Model............................................118
5.1.2 Tool Design Principles.......................................................................120
5.1.3 The Tool Design for New Machining Technologies..........................123
5.2 Tool Materials............................................................................................124
5.2.1 High Speed Steel................................................................................124
5.2.2 Cemented Carbide..............................................................................124
5.2.3 Cermet................................................................................................125
5.2.4 Ceramics............................................................................................125
5.2.5 Diamond.............................................................................................126
5.2.6 Cubic Boron Nitride...........................................................................127
5.3 High-performance Coated Tools................................................................127
5.3.1 Tool Coating Methods.......................................................................128
5.3.2 The Cutting Performance of PVD Coated Tools...............................129
5.3.3 The Cutting Performance of CVD Coated Tools...............................132