制造自动化：金属切削力学、机床振动和CNC设计（第二版）（英文版）

第1章为绪论；第2章介绍了金属切削过程力学的基本理论及原理；第3章讨论了切削加工过程中的静态变形和振动；第4章分别从频率域和离散时域两个方面介绍了正交切削和斜向切削的颤振理论；第5章介绍了数控技术及其操作和编程原理；第6章介绍了CNC系统设计的基本原理，详细介绍了进给伺服机构的数学模型；第7章介绍了传感器辅助加工，机床上安装了多种传感器，可以测量机械加工过程中的力、振动、温度和声音等。本书论述了金属切削的科学原理及其在解决制造过程中遇到的问题。数学、物理、计算机、仪器仪表等学科被认为是分析或设计机床和制造过程的集成工具。

《制造自动化：金属切削力学、机床振动和CNC设计（第二版）（英文版）》从切削过程力学的基本原理开始，深度讨论了振动及颤振问题；也讨论了数控编程和计算机辅助设计/计算机辅助制造（CAD/CAM）技术。文中还详细介绍了驱动执行机构、反馈传感器的选择、进给驱动系统的建模与控制、轨迹实时生成和插补算法的设计、面向数控系统的误差分析等。每一章都包括从企业实际、设计项目和工作问题中筛选的案例。

《制造自动化：金属切削力学、机床振动和CNC设计（第二版）（英文版）》特别适合于高年级本科生和研究生，以及研发工程师阅读，并能帮助读者在这本书中找到清晰而彻底的方式来学习金属切削力学的工程原理、机床振动、数控系统设计、传感器辅助加工，以及CAD/CAM技术等。

Yusuf Altintas教授现任加拿大皇家科学院（RSC）院士、国际生产工程学会（CIRP）主席、加拿大工程院院士、美国机械工程师学会（ASME）和国际制造工程师学会（SME）会士，加拿大英属哥伦比亚大学机械工程系终身教授。Yusuf Altintas教授是享誉世界的制造领域著名专家，主要研究方向为金属切削、机床振动、控制和虚拟加工等，其著作Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design, Second Edition被广泛使用。他领导的实验室开发了先进加工过程仿真工具（CUT*PRO）、虚拟加工过程仿真工具（MACH*PRO），以及开放式模块化数控加工系统（Virtual CNC），这些产品已被全球机械加工领域超过200家公司和研究机构使用。

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 Structures....................66

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?........83

4.4 Analytical?Modal?Analysis?for?MultiCDegree-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 MultiCDegree-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?Cutting.................132

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 Problems...............186

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?Geometry..................................201

5.3.2 APT?Part?Programming?Language?...................................206

5.4 Trajectory Generation for Computer-Controlled Machines?...........................211

5.4.1 Interpolation?with?Constant?Displacement....................................212

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