Brecher C., Weck M. Machine Tools Production Systems 2: Design, Calculation and Metrological Assessment

New York: Springer, 2022. — 850 p.The first part of this volume provides the user with assistance in the selection and design of important machine and frame components. It also provides help with machine design, calculation and optimization of these components in terms of their static, dynamic and thermoelastic behavior. This includes machine installation, hydraulic systems, transmissions, as well as industrial design and guidelines for machine design. The second part of this volume deals with the metrological investigation and assessment of the entire machine tool or its components with respect to the properties discussed in the first part of this volume. Following an overview of the basic principles of measurement and measuring devices, the procedure for measuring them is described. Acceptance of the machine using test workpieces and the interaction between the machine and the machining process are discussed in detail.
The German Machine Tools and Manufacturing Systems Compendium has been completely revised. The previous five-volume series has been condensed into three volumes in the new ninth edition with color technical illustrations throughout. This first English edition is a translation of the German ninth edition.Requirements and Designs
Structural Components and Assemblies
Design and Layout Criteria for Static Loads
Static Loads
Static Parameters
Force Flux and Deformation Analysis
Aspects of Structural Design
Stiffness in Beams
Ribbing Strategy
Force Introduction
Joints
Number and Arrangement of Bolts in the Flange
Stiffness of Individual Bolted Connections
Flange Design
Design Principles
Design and Layout Criteria for Dynamic Loads
The Basics of Dynamic Behavior
Dynamic Parameters
Aspects of Structural Design
Masses and Mass Distribution
Damping in Frames
Design and Layout Criteria for Thermal Loading
Thermal Parameters
Aspects of Structural Design
Calculation and Optimization of Frame Components
Calculation of Frame Components
Introduction to the Finite Element Method
Calculating the Static Behavior of Structural Components
Deriving an Element Stiffness Matrix
Overlaying the Element Stiffness Matrices on the Total Stiffness Matrix
Calculating the Dynamic Behavior of Machine Tools
Modal Analysis
Calculating the Frequency Response from Modal Parameters
Static Condensation
Calculating the Kinematics of Machine Tools
Flexible Multi-Body Simulation
Calculating the Interactions Between Structural Dynamics and Machine Control Systems
Calculating the Interaction Between Structural Dynamics and the Machining Process
Calculating the Thermoelastic Behavior
Calculation Examples
Calculating the Static Behavior of Frame Components
Calculating the Dynamic Behavior of Frame Components
Calculating the Interaction Between Control and Structural Dynamics
Calculating the Thermoelastic Behavior of Frame Components
Calculation Accuracy and Possible Errors
Optimizing the Mechanical Component Behavior
Basic Principles of Optimization
Structural Optimization in the Machine Tool Industry
Sizing
Mass/Stiffness Optimization of Components by Adjusting Wall Thicknesses
Optimization of Components made from Fiber-Reinforced Composites
Shape Optimization
Reducing Stress at Open Fillets Using the Theory of Notch Stresses
General Approach to Shape Optimization of Components Using Base Shapes
Shape Optimization of Components Taking Geometrical Restrictions into Consideration
Topology Optimization
Two-Dimensional Stiffness Optimization of Component Cross-Sections
Optimizing the Topology of Larger Three-Dimensional Components
Transferring Design Proposals Back into the CAD Environment
Material-Based Design
Material Properties of Steel and Cast Iron Materials
Designing with Steel Materials
Welded Structures
Designing with Cast Iron
Material Properties of Concretes
Cement Concrete
Reaction Resin Concrete
Designing with Concrete Materials
Shuttering Concrete Components
Connecting Concrete and Steel
Fiber-Reinforced Plastics
Material Characteristics
Criteria and Options for Using Highly-Loaded Machine Elements made from Fiber-Reinforced Plastics
Design and Production of Fiber-Reinforced Plastic Components and Application Examples
Introduction of Forces
Production Processes
Working with Thermosetting Plastics
Working with Thermoplastics
Areas of ApplicationInstallation and Foundation of Machine Tools
Components for Machine Installation
Installation Elements
Foundation
Subsoil
Foundation Design Under Static Considerations
Foundation Design Under Dynamic Considerations
Assessment Criteria for Vibrations
Design of Active Vibration Isolation
Design of Passive Vibration IsolationHydraulics
Basic Principles of Hydraulics
Fundamental Operational Equations for Hydraulic Machines
Pump Curve
The Notion of Viscosity
Hydraulic Machines
Rotary Gear Pumps and Annular Gear Pumps
Vane Pumps
Piston Displacement Units
Axial Piston Pumps
Radial Piston Pumps
Hydraulic Drive Systems
Linear Hydraulic Drive Systems
Adjusting the Speed of Hydraulic Machines
Changing the Speed by Adjusting Pump and Motor Volumes
Primary or Pump Adjustment
Secondary or Motor Adjustment
Motor Speed Adjustment by Controlling the Volume Flow Rate
Circuits
Types of Control
Resistance Control
Displacement Control
Control System Types
Bang-Bang Control
Bypass Control
Pressure and Volume Flow Rate Control by Adjusting the Swing Angle
Rotational Speed Control Using a Frequency Converter
Valves
Valve Functions and Their Operating Principles
Directional Control Valves
Discrete Valves
Continuous Valves
Servo Valve Functionality
Proportional Control Valve Functionality
Piezo Valve Functionality
Pressure Valves
Flow Control Valves
Check Valves
Hydraulic Accumulators
Cylinders
Filters
Compact Pumping UnitsGuide Systems, Bearing Arrangements and Feed Systems
The Basic Principles of Tribology
Hydrodynamic Pressure Build-Up
Types of Friction
Stribeck Curve
Stick-Slip Effect
Hydrodynamic Plain Guide Systems and Plain Bearings
Hydrodynamic Plain Guide Systems
Materials for Plain Guide Systems
Tribological Properties
Designs
Clamping Devices
Compensating Guidance Errors
Static and Dynamic Behavior
Hydrodynamic Plain Bearings
Pressure Build-Up and Start-Up Process
Designs
Hydrodynamic Spindle-Bearing Systems in Machine Tools
Calculating Multi-Surface Bearings
Hydrostatic Plain Guide Systems and Plain Bearings
Basic Principles, Functional Principle and Terminology
Oil Supply Systems
Bearing Calculation
Oil Supply System “One Pump Per Pocket” Without Wrap-Around
Oil Supply System “Pump With Pre-Throttle” Without Wrap-Around
Oil Supply System “One Pump Per Pocket” With Wrap-Around
Oil Supply System “Pump With Pre-Throttle” With Wrap-Around
Calculation Example
Damping in a Hydrostatic Pocket
Energy Requirement and Hydraulic Circuit
Hydrostatic Linear Guides
Design Features and Types
Application Examples
Hydrostatic Bearings
Designs
Pressure Build-Up
Bearings with Structured Bearing Surfaces
Bearing Design
Sealing
Hydrostatic Spindle-Bearing Systems
Combined Hydrostatic Radial-Axial Bearings
Hydrostatic Spindle-Nut Systems
Aerostatic Plain Guide Systems and Plain Bearings
Basic Principles, Functional Principle and Terminology
Design and Calculation
Dynamic Stability in Aerostatic Plain Guide Systems and Plain Bearings
Application Examples
Rotary Tables with Aerostatic Bearing Support
Spindle-Bearing Systems With Aerostatic Bearing Support
Aerostatic Linear Guides
Electromagnetic Bearings
Basic Principles, Functional Principle and Terminology
Application Example
Rolling Element Guide Systems and Rolling Element Bearings
Rolling Element Guide Systems
Types of Rolling Element Guide Systems
Longitudinal Guide
Linear Guide System With Rollers or Balls
Sealing Technology and Lubrication of Linear Guide Systems
Integral Distance Measuring Systems
Clamping and Braking Elements
Recirculating Roller Bearings
Linear Recirculating Ball Bearings
Track Roller Guide Systems
Rolling Bearings for Main Spindle Applications
Bearing Designs and Their Characteristics
Design of the Bearings’ Surrounding Components
Bearing Clearance and Stiffness
Bearing Clearance
Stiffness and Preload
Stiffness Curves for Selected Bearings
Operating Behavior
Kinematic Behavior
Bearing Friction
Changes in the Kinematics in a Spindle Bearing During Operation
Slip and Acceleration Behavior
Damping in Rolling Element Bearings
Rolling Bearings as Vibration Generators
Calculating the Operating Life of Rolling Element Bearings
Lubricating Spindle Bearings
Types of Lubrication
Lubricant Feed Systems
Bearing Seals and Rotating Machine Elements
Contact Seals
Non-Contact Seals
Main Spindles With Rolling Bearing Supports
Design and Behavior of the Bearing Arrangement
Bearing Arrangement and Mounting
Design of Non-Locating Bearing Arrangements
Thermal and Kinematic Behavior
System Behavior
Thermal and Kinematic Behavior
Static Behavior
Dynamic Behavior
Calculating the System Behavior
Measures for Optimizing the Operating and System Behavior
Static and Dynamic System Behavior
Modified Spindle Bearings for High Rotational Speeds
Modified Radial Bearings for High Rotational Speeds
Rotating Unions
Ball Screw Drives
Basic Principles, Functional Principle and Terminology
Design and Calculation
Load Carrying Capacity and Operating Life of Ball Screw Drives
Sealing and Lubrication
Roller Screw Drives
Planetary Roller Screw
Recirculating Roller Screw Drives
Planetary Screw Drives
Covering Guide ElementsTransmissions
Uniform Transmissions
Gearboxes with Incrementally Adjustable Output Speeds
Fundamental Designs of Multi-Speed Transmissions
Fundamental Principles for the Calculation of Stepped Transmissions
Transmissions With Steplessly Adjustable Output Speeds
Electrical Transmissions
Hydraulic Transmissions
Mechanical Transmissions
Combination of Stepped Transmissions With Stepless Drive Motors
Example Applications for Uniform Transmissions
Non-Uniform Transmissions
Oscillating Slotted Link Mechanism
Slider Crank
Toggle Levers
Cam Plates
Non-Circular Gears
Harmonic Drive and Cycloid GearingIndustrial Design and Guidelines on Machine Design
Industrial Design
Machine Paneling
Corporate Design
Design Guidelines
Ergonomics
Development Cycle in the Design Process
Guidelines for Machine Design by Way of Example (the EC Machinery Directive)
Legal Framework Conditions
Explanation of Terms in Conjunction with the Machinery Directive
The Product Liability Act
Precedence Principle of Special Directives
Presumption of Conformity
The CE Mark
Environmental Directives
Overview of the EC Machinery Directive //EC
Scope of the Machinery Directive
Manufacturer Obligations Prior to Putting Machinery onto the Open Market
Machinery Directive Annexes With a Relevance to Manufacturers
Performing a Risk Assessment
Specification of the Machine Boundaries
Identification of Hazards
Risk Evaluation
Risk Assessment
Risk Reduction
Documentation of ResultsMethods and Instruments Used for the Measurement of Machine Properties
Significance of machine assessment and acceptance
Requirements on measuring methods and implementation procedures
Direct measurement of machine properties
Indirect measurement of machine properties
Standards, standard committees
Methodological principles
Description of linear, time-invariant systems (LTI systems)
Convolution and correlation
Laplace transform
The Fourier series and Fourier integral
Working with discrete signals
Analog/digital transformations
Shannon’s theorem and aliasing
Discrete Fourier transform
Fast Fourier transform
Devices for measuring displacements
Mechanical displacement measuring devices
Potentiometer displacement sensors
Capacitive displacement sensors
Eddy current displacement sensors
Inductive displacement sensors
Optical displacement measuring devices
Laser interferometer
Position-sensitive diodes
Triangulation sensors
Confocal sensor technology
The tracking interferometer
Incremental linear scale
Photogrammetry
Equipment for measuring angles
Electronic inclination balance
Optical angle transducers
Autocollimator
Incremental angle encoder
Equipment for measuring speeds
Electrodynamic transmitter
Laser Doppler vibrometer
Equipment for measuring accelerations
Equipment for measuring forces
Strain gauges
Piezoelectric quartz
Sensors for measuring temperatures
Contact temperature measurement
Non-contact temperature measurement
Current and power measurementGeometric and Kinematic Behavior of Machine Tools
Geometric Deviations
General Description of Systematic Deviations
Movement Along One Axis
Movement Along Multiple Axes
Statistical Description of Deviations
Statistical Analysis
Considerations of Measurement Uncertainty
Determination of Workpiece Dimension Errors from the Geometric Machine Deviations
Measuring Methods for Determining Geometric Machine Properties
General Interrelationships for the Measurement of Machine Properties
Measuring Linear Axes
Measuring Method with a Representative Standard
Measuring Method with Autocollimator
Measuring Method with Laser Interferometer
Measuring Method with Incremental Linear Encoder
Measuring Method with Position-Sensitive Diode (PSD)
Measuring Method with Electronic Inclination Balance
Measuring the Straightness/Flatness of the Table
Measuring Method with Autocollimator
Measuring Method with a Representative Standard
Measuring Method with Position-Sensitive Diode (PSD)
Measuring Method with Electronic Inclination Balance
Measuring Rotation Axes
Basics and Definitions
Repeatable and Non-repeatable Runout Errors
Measurements of True Running Deviations, Axial Error Motion and Axial Runout According to DIN
Measuring Method with Test Ball or Test Cylinder
Measuring Method with Laser Interferometer
Measuring Method with Position-Sensitive Diode (PSD)
Volumetric Measurement of Geometric Errors
Gauging the Workspace with an Adapted Measurement Standard
Volumetric Measurement with Tracking Interferometers
Kinematic Deviations
Measuring Methods for Determining Kinematic Machine Properties
Time Base Measurements with Spatial Frequency Analysis
Feed Error Measurement on a Lathe (Rotatory-Translational Motions)
Rotational and Feed Error Measurement on a Hobbing Machine (Rotatory-Rotatory-Translational Motions)
Measuring -Axis Interpolation (Translational-Translational Motions)
Circular Test
Multiple-Axis Tests in Accordance with ISO -Static Behavior of Machine Tools
Measuring the Influence of the Workpiece Weight
Measurement of Static Process Load Influence
Weak-Point Analysis of Statically Loaded Machine Components
Quasi-Static Load Deformation AnalysisThermoelastic Behavior of Machine Tools
Thermal Effects on Machine Tools
Metrological Investigation of the Thermoelastic Deformation Behavior
Measurement of Thermoelastic Displacements at the Cutting Point
Measuring Thermoelastic Structural Deformations
Temperature Development and Deformation Behavior
Temperature Development and Deformation Behavior at the Cutting Point as a Result of Internal Heat Sources
Temperature Development and Deformation Behavior at the Cutting Point as a Result of External Heat Sources
Correction and Compensation of Thermoelastic DisplacementsThe Dynamic Behavior of Machine Tools
Types of Vibration and Their Causes
Determination of Frequency Response
H, H Approximations
Coherence
Types of Test Signals and Exciters
Forms of Excitation
Excitation Types
FRF Measurement Specification
State of the Art as Regards Machine Compliances
Experimental Modal Analysis
Determination of Damping Given Pronounced Single-mass Oscillator Behavior
Half Power Bandwidth Method
Decay Curve
SIMO and MIMO Identification Methods
Procedure for Identifying Local Damping Characteristics
Dynamic Machine Behavior When Machining With Defined Cutting Edge Geometry
Loop for the Regenerative Force Feedback of Metal-cutting Machine Tools
Self-excited Vibrations Due to Position Coupling
Experimental Assessment of the Static and Dynamic Machine Behavior During Machining Processes
Procedure for Determining the Threshold Cutting Capacity
Practical Example of an Efficient Method for Experimental Determination of the Static Machine Deformation and Threshold Cutting Capacity
Calculation of the Stability Behavior Using Measured Compliance Frequency Responses
Fundamentals of the Simulative Stability Forecast for the General Process Application
Calculation of Process Stability in the Frequency Domain
Simulation of Process Stability in the Time Domain
Modeling of Machine Compliance in the Time Domain
Modeling of the Cutting Process in the Time Domain
Externally-excited Vibrations When Machining With Defined Cutting Edge
Dimensional and Form Deviations Due to Dynamic Compliance Behavior When Drill-finishing Holes
Dimensional and Form Deviations of the Hole Due to the Cutting Force
Dimensional and Form Deviations of the Hole Due to Imbalance Forces
Process Stability When Machining With Undefined Cutting Edge Geometry (Grinding)
Description of the Regenerative Effect When Machining With Undefined Cutting Edge Geometry
System Compliance Behavior for Grinding Machine, Grinding Disk and Workpiece
Geometry of Dynamic Contact Conditions During the Grinding Process
Determination of Crossover and Lift Frequencies
Representation of the Dynamic Material Removal Rate in the Complex Plane
Wave Formation on the Workpiece
Threshold Phase Curve for Chatter on Workpiece Side
Wave Formation on the Grinding Disk
Threshold Phase Curve for Chatter on Grinding Disk Side
Threshold Phase Relationship for the Longitudinal Grinding Process
Threshold Phase Relation for Centerless Throughfeed Grinding
Measures for Increasing Process Stability
Factors Influencing Chatter
Design Measures
Dynamic Supplementary Systems
Overview of Dynamic Supplementary Systems
Passive Supplementary Systems
Active Supplementary Systems
Measures on the Process Side
Optimization of the Process Parameters
Tools With Uneven Spacing
Rotational Speed Variation
Peculiarities of Grinding ProcessesMachine Acceptance with Test Workpieces
Acceptance workpieces and test workpieces
Test workpieces for determining operational and positional accuracy
Test workpieces for machines for high-speed and micro machining
Methods for performing capability studies
Basic principles and procedures
Influencing factors
Measuring equipment for determining the quality of a component
Statistical methods
Standardized acceptance guideline VDMAAcoustic Behavior of Machine Tools
Basic Acoustics Terms
Sound Characteristics
Spectral Composition of Sound
Analysis and Weighting of Noise
Time Weighting
Frequency Weighting
Assessment of Time-varying Noises
Sound Measurement Techniques for Determining Noise Emissions From Machines
Analysis Measurement Techniques
Noise Measurements in Accordance With DIN
Sound Pressure Measurement
Sound Intensity Measurement
Acoustic Camera
Locating Sound Components and Inferences About Noise Excitation in Relation to Machinery
Omnidirectional Measurement in the Far Field
Omnidirectional Measurement in the Near Field
Measurement of the Structure-borne Sound
Determination of Sound Components
Narrow-band Analyses
Coherence Analyses
Acoustic Behavior Assessment of Machine Tools
Hearing-oriented Noise Assessment
Volume and Loudness
Tonality and Tonal Noise
Sharpness
Fluctuation Strength and Roughness
Application of Psychoacoustic Parameters
Hearing-oriented Noise Assessment Measurement Set-up
Low-noise Machine Design
Fundamentals
Examples of Noise Reduction
Technical Aspects of Machines
Process Engineering AspectsFormula Directory