Presents new developments on machine tool vibration control based on discontinuous dynamical systems Machining instability is a topical area, and there are a wide range of publications that cover the topic. However, many of these previous studies have started by assuming that the behavior of the system can be linearised. Meanwhile, there are many recent advances in the fields of signal processing, nonlinear dynamics, and nonlinear control, all of which are relevant to the machining stability problem. This book establishes the fundamentals of cutting mechanics and machine tool dynamics in the simultaneous time-frequency domain. The new nonlinear control theory developed by the authors that facilitates simultaneous control of vibration amplitude in the time-domain and spectral response in the frequency-domain provides the foundation for the development of a controller architecture universally viable for the control of dynamic instability including bifurcation and chaos. Once parameters underlying the coupling, interaction, and evolution of different cutting states and between the tool and workpiece are established, they can then be incorporated into the architecture to create a control methodology that mitigate machining instability and enable robust, chatter-free machine tool design applicable in particular to high speed micro- and nano-machining. Presents new developments on machine tool vibration control based on discontinuous dynamical systems Provides a clear and concise approach to the understanding and control of machine tool and workpiece vibrations from an alternative view, contributing to an in-depth understanding of cutting dynamics and robust control of machining instability Equips the reader with the knowledge to understand the dynamics of cutting and operation of machine-tool systems in different conditions as well as the concept of cutting instability control Includes data examples in MATLAB coding

“Machine Tool Vibrations and Cutting Dynamics” covers the fundamentals of cutting dynamics from the perspective of discontinuous systems theory. It shows the reader how to use coupling, interaction, and different cutting states to mitigate machining instability and enable better machine tool design. Among the topics discussed are; underlying dynamics of cutting and interruptions in cutting motions; the operation of the machine-tool systems over a broad range of operating conditions with minimal vibration and the need for high precision, high yield micro- and nano-machining.

Metal cutting is widely used in producing manufactured products. The technology has advanced considerably along with new materials, computers and sensors. This new edition considers the scientific principles of metal cutting and their practical application to manufacturing problems. It begins with metal cutting mechanics, principles of vibration and experimental modal analysis applied to solving shop floor problems. There is in-depth coverage of chatter vibrations, a problem experienced daily by manufacturing engineers. Programming, design and automation of CNC (computer numerical control) machine tools, NC (numerical control) programming and CAD/CAM technology are discussed. The text also covers the selection of drive actuators, feedback sensors, modelling and control of feed drives, the design of real time trajectory generation and interpolation algorithms and CNC-oriented error analysis in detail. Each chapter includes examples drawn from industry, design projects and homework problems. This is ideal for advanced undergraduate and graduate students and also practising engineers.

Machine Tool Structures, Volume 1 deals with fundamental theories and calculation methods for machine tool structures. Experimental investigations into stiffness are discussed, along with the application of the results to the design of machine tool structures. Topics covered range from static and dynamic stiffness to chatter in metal cutting, stability in machine tools, and deformations of machine tool structures. This volume is divided into three sections and opens with a discussion on stiffness specifications and the effect of stiffness on the behavior of the machine under forced vibration conditions. The following chapters explore the stability of the machine structure against chatter; methods of stability analysis; tests and principles of dampers; chatter during grinding operations; and stresses and deformations of closed box structures subjected to bending and shear. Calculation methods for determining stiffness constants of a structure's individual parts, as well as methods for determining the resulting stiffnesses, modal shapes, and their parameters, are also described. The final chapter presents systematic procedures for the analysis of machine tool structures. This book is intended for university students, research workers, and designers.

This book focuses on the state-of-the-art developments in machining with nanomaterials. Numerous in-depth case studies illustrate the practical use of nanomaterials in industry, including how thin film nanostructures can be applied to solving machining problems and how coatings can improve tool life and reduce machining costs in an environmentally acceptable way. Chapters include discussions on, among other things: Comparisons of re-coated cutting tools and re-ground drills The modeling and machining of medical materials, particularly implants, for optimum biocompatibility including corrosion resistance, bio adhesiveness, and elasticity Recent developments in machining difficult-to-cut materials, as well as machining brittle materials using nanostructured diamond tools Spindle Speed Variation (SSV) for machining chatter suppression Nano grinding with abrasives to produce micro- and nano fluidic devices. The importance of proper design of cutting tools, including milling tools, single point turning tools, and micro cutting tools is reinforced throughout the book. This is an ideal book for engineers in industry, practitioners, students, teachers, and researchers.

The first book to comprehensively address the theory, kinematic modelling, numerical simulation and applications of vibration assisted machining Vibration Assisted Machining: Theory, Modelling and Applications covers all key aspects of vibration assisted machining, including cutting kinematics and dynamics, the effect of workpiece materials and wear of cutting tools. It also addresses practical applications for these techniques. Case studies provide detailed guidance on the design, modeling and testing of VAM systems. Experimental machining methods are also included, alongside considerations of state-of-the-art research developments on cutting force modeling and surface texture generation. Advances in computational modelling, surface metrology and manufacturing science over the past few decades have led to tremendous benefits for industry. This is the first comprehensive book dedicated to design, modelling, simulation and integration of vibration assisted machining system and processes, enabling wider industrial application of the technology. This book enables engineering students and professionals in manufacturing to understand and implement the latest vibration assisted machining techniques. Highlights include: Comprehensive coverage of the theory, kinematics modelling, numerical simulation and applications of vibration assisted machining (VAM) Case studies with detailed guidance on design, modelling and testing of VAM systems, as well as experimental machining methods Discussion of state-of-the-art research developments on cutting force modelling and surface texture generation Coverage of the history of VAM, its current applications and future directions for the technology Vibration Assisted Machining: Theory, Modelling and Applications provides engineering students, researchers, manufacturing engineers, production supervisors, tooling engineers, planning and application engineers and machine tool designers with the fundamentals of vibration assisted machining, along with methodologies for developing and implementing the technology to solve practical industry problems.

Machining dynamics play an essential role in the performance of the machine tools and machining processes which directly affect the removal rate, workpiece surface quality and dimensional and form accuracy. Machining Dynamics: Fundamentals and Applications will be bought by advanced undergraduate and postgraduate students studying manufacturing engineering and machining technology in addition to manufacturing engineers, production supervisors, planning and application engineers, and designers.

Metal cutting applications span the entire range from mass production to mass customization to high-precision, fully customized designs. The careful balance between precision and efficiency is maintained only through intimate knowledge of the physical processes, material characteristics, and technological capabilities of the equipment and workpieces involved. The best-selling first edition of Metal Cutting Theory and Practice provided such knowledge, integrating timely research with current industry practice. This brilliant reference enters its second edition with fully updated coverage, new sections, and the inclusion of examples and problems. Supplying complete, up-to-date information on machine tools, tooling, and workholding technologies, this second edition stresses a physical understanding of machining processes including forces, temperatures, and surface finish. This provides a practical basis for troubleshooting and evaluating vendor claims. In addition to updates in all chapters, the book features three new chapters on cutting fluids, agile and high-throughput machining, and design for machining. The authors also added examples and problems for additional hands-on insight. Rounding out the treatment, an entire chapter is devoted to machining economics and optimization. Endowing you with practical knowledge and a fundamental understanding of underlying physical concepts, Metal Cutting Theory and Practice, Second Edition is a necessity for designing, evaluating, purchasing, and using machine tools.