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Machining processes are industrial processes in which typically metal parts are shaped by removal of unwanted materials. They are still the fundamental manufacturing techniques and it is expected to remain so for the next few decades. According to the International Institution of Production Research (CIRP), machining accounts for approximately half of all manufacturing techniques, which is a reflection...
This chapter starts with an introduction of the machine-tool-workpiece loop stiffness and deformation, and then fundamentals of vibrations and followed by the definition and categories of machining chatter. It is not the purpose of this chapter to present the general theory of vibration and chatter in depth as there are a number of excellent books and papers available on these subjects. It is intended...
All machining processes are subject to dynamic effects due to transient or forced vibrations, and dynamic mechanisms inherent to the process such as regeneration. If not controlled, they may result in high amplitude oscillations, instability and poor quality. Dynamic rigidity of the structures involved in the machining is very important in determining the dynamic behaviour of the process. Structural...
There are two reasons why it is important to diagnose, identify, or analyse the dynamic behaviour of machine tools. Firstly, the many techniques that can be used to optimise the machining process invariably require some model of the structural dynamics. This is especially true for the problem of avoiding unstable chatter vibrations, and for predicting the surface finish. Knowledge of the structure’s...
Metal cutting is a process of removing material from a workpiece in the form of chips using single- or multi-point cutting tools with a clearly defined geometry. To some extent, the performance of a cutting tool determines the cutting behaviour and the process capability. In order to design high-performance cutting tools, it is important to clearly understand the tool-workpiece interfaces and the...
The dynamic stability of a machine tool in the turning process depends essentially on the compliance of the lathe turning structure, as well as on the properties of the cutting process [1]. However, the design of the machine tool, the material(s) employed for its manufacture and their mechanical properties are extremely important for the dynamic behaviour of the machining system (comprising the entire...
The milling process is distinguished by a rotating tool with one or more teeth that removes material while travelling along various axes with respect to the workpiece. The engagement of each tooth with the workpiece is discontinuous in the milling process different to the turning process. As a tooth engages the workpiece, it receives a shock followed by a varying cutting force. The cyclic shock and...
Grinding has traditionally been a finishing operation, as it is today for many precision parts. With the advance of technology, grinding has extended its application to a roughing process. Today the grinding process has been successfully applied to almost all types of material removing processes with an extremely high material removal rate of more than 3,000 mm3/(mm s) and ultraprecision accuracy...
With the advances in the micro electronic and computer technologies, the design and fabrication of ultra-precision machines have been improving dramatically over the past several decades. However, these have not been parallel with the development and the understanding of the physical mechanism of the micro and nano-cutting process and how to obtain a quality surface with the surface finish down to...
Precision machines are essential in modern industry and directly affect machining accuracy, repeatability, productivity and efficiency. Generally, the design of a precision machine mainly includes the design of its key elements such as mechanical structure, spindles and drive system, control and inspection systems, etc. There is a lot of literature available on the design of machine elements [1-5];...
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