Seesdiscussions,sstats,sandsauthorsprofilessforsthisspublicationsat:shttps://www.researchgate.net/publication/286842300
Machine Tools for Machining s s s
Chapters·sSeptembers2015
DOI:s 10.1007/978-1-4471-4670-4_4
CITATIONS READS
0 33,610
2sauthors:
IrvingsPaulsGirsangsTh JaspreetsSinghsDhupias
esBluesCircle UniversitysofsAuckland
12sPUBLICATIONSs 91sCITATIONS 39sPUBLICATIONSs 324sCITATIONS
PROFILE PROFILE
Somesofsthesauthorssofsthisspublicationsaresalsosworkingsonsthesesrelatedsprojects:
WindsTurbinesElectromechanicalsModelingsViewsproject
AllscontentsfollowingsthisspageswassuploadedsbysJaspreetsSinghsDhupiasons20sJanuarys2016.
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,Machine Tools for Machining
s s s
20
IrvingsPaulsGirsangsandsJaspreetsSinghsDhupia
Contents
Introduction ................................................................................................................................ 812
MachinesToolsOperations ........................................................................................................... 814
MachinesswithsSingle-PointsCuttingsTools ........................................................................... 814
MachinesswithsMultipointsTools ........................................................................................... 824
MachineswithsGrindingsWheels ............................................................................................ 841
MachiningsCenters ................................................................................................................ 847
MachinesToolsStructures ............................................................................................................ 849
SpindlesDrives ...................................................................................................................... 850
FeedsDrives ........................................................................................................................... 851
NumericalsControls ............................................................................................................... 853
NontraditionalsMachinesTools ................................................................................................... 855
IndustrialsRobots................................................................................................................... 855
ParallelsandsHybridsKinematicsMachinesTools ..................................................................... 859
ReconfigurablesMachinesTools ............................................................................................. 860
Summary.................................................................................................................................... 864
References.................................................................................................................................. 864
Abstract
Machiningsoperationssaresamongsthesmostsversatilesandsaccuratesmanufacturingsp
rocessessinstermssofsitsscapabilitystosproducesdiversesandscomplexsgeometricsfeat
ures.sThisschapterstakessitssfocussonsthesmachiningsprocessessutilizingssharpscutti
ngstoolsstosremovesmaterialssfromsthesworkpiecesbysshearsdeformation.s Thesmai
nsprinciplesofsthesesprocessessissprovidingsthesrelativesmotionssbetweensthescuttin
gstoolsandsthesworkpiece,swhichsissaccomplishedsthroughsmachinestools.s Thes ma
chines toolss ares discusseds ands categorizeds baseds ons thes employed
I.P.sGirsangs( )s•sJ.S.sDhupia
SchoolsofsMechanicalsandsAerospacesEngineering,sNanyangsTechnologicalsUniversity,sSingapores
e-mail:;
ⒸsSpringer-Verlags Londons 2015 811
A.Y.C.sNees(ed.),sHandbooksofsManufacturingsEngineeringsandsTechnology,s
DOIs10.1007/978-1-4471-4670-4_4
,812 I.P.sGirsangsandsJ.S.sDhupia
cuttingstools:ssingle-
pointscuttingstools,smultipointscuttingstools,sorsgrindingswheels.sMachiningscente
rs,swhichshavesflexibilitiesstosperformsvarioussmachin-
singsoperationsswithsdifferentscuttingstoolssonsmoresthansone sworkpiece,saresalsosd
iscussed.sDrivessandscontrolssaresresponsiblestosrespectivelysprovidesandsregulate
sthesmotionssofsthesmachinestoolscomponents.sThus,sindustrialsdesignssandstechno
logiessofsspindlesdrivessandsfeedsdrives,sasswellsassnumericalscontrols,saresdescribe
dsinsthisschapter.sFinally,sdifferentsmechanicalsdesigns,sinstermssofstheskinematics
mechanismstosprovidesthesrelativesmotionssbetweensthestoolsandsthesworkpiece,sh
avesbeensintroducedstosthesmanufacturingsfloors.sEachsofsthesesdesignsshasspenet
ratedstoday’ssmanufacturingsfloorsbringingscertainssuperioritysasscomparedstosthes
conventionalsmachinestools.sThisschaptersdiscussessimportantscharacteristicssofsasf
ewsofsthesesemergingsmachinestoolsdesigns,snamely,sindus-
strialsrobots,sparallelsandshybridskinematic smachinestools,sand sreconfigurablesma
chinestools.
Introduction
DevelopmentsofsmachinestoolssforsmanufacturingswasscloselysrelatedstosthesIndus-
strialsRevolution,swhichsissmarkedsbysthessuccessfulsdevelopmentsofssteamsenginesb
ysJamessWattsins1776.sWhenshesstartedsdesigningsthessteamsenginesins1763,shissprim
aryschallengeswasstosmakesthesboresofsthescylinderssufficientlysaccuratestospreventsth
essteamsfromsescapingsaroundsthespiston.sThesinitialscylinderswassmanufacturedsfro
mssheetsmetal,swhichscertainlysdidsnotsworksproperly.sThesprob-
slems wasseventuallyssolvedsbysJohnsWilkinsonswhenshesinventedsaswaterwheel-
spoweredshorizontal-
axissboringsmachinesarounds1775.sThissmachinesissoftensrecognizedsassthesfirstsmac
hinestool.
Sincesthen,smachiningsprocesssandsmachinestoolshavesalwayssbeensessentialsinspr
oductsdesignsandsmanufacturing.sSomesevensarguesthatsmachiningsissthesmostsversat
ilesandsaccuratesofsallsmanufacturingsprocessessinstermssofsitsscapabilitystosproduces
diversesgeometricsfeatures.sFurther,spartssmanufacturedsbyscasting,sforming,sorsothe
rsshapingsprocessessoftensrequiresmachiningsoperationssbeforesbeingsassembledsforst
hesfinalsproduct.sThissfinalsmachiningsoperationsissrequiredsbecausesthespartssmaysh
avesexternalsandsinternalsprofiles,sasswellsasssharpscornerssandsflatnesssthatscannotsb
esaccuratelysachievedsbysformingsandsshapingsprocesses.sAlso,sbecausesmanysengin
eeringscomponentssorspartssneedstosbesinterchangeable,sitsrequiresscontrolsofsdimensi
onalsaccuracy,swhichscansbesachievedsthroughsmachin-
singsprocess.sTherefore,scriticalschoicesshavestosbesmadesduringsproductsdesignsands
manufacturingsplanningsaboutsthesextentsofscasting,sshaping,sorsformingsagainststhese
xtentsofsmachiningstosbesdonesonsasworkpiece.
Machiningsissthesgeneralstermsusedstosdescribesthesmaterialsremovalsprocesssfrom
sasworkpiece,swhichsissaswidestopic.sInsthe sinterestsofsasfocusedsdiscussion,sthesscopes
ofsthisschaptersisslimitedstosthesprocessessusingssharpscuttingstoolsstosformsaschipsfro
msthesworkpiecesbysshearsdeformation.sThisschaptersalsosdescribessthesmachines too
lss tos performs theses machinings operations.s Besidess thes operations
, 20s MachinesToolssforsMachining 813
Fig.s1s Coordinatessystemsforsmotionssofs(a)stoolsands(b)sworkpiece
describedsinsthisschapter,sothersmechanismsscansbesappliedstosremovesmaterialsotherst
hansusingssharpscuttingstool.sThesesalternativesmechanismssmaysinvolvesthesusesofsm
echanicals(e.g.,sultrasonicsorswatersjetsmachining),sthermals(e.g.,selectricalsdis-
scharge,selectronsbeam,slasersbeam,sarc,sorsoxyfuelsmachining),selectrical,sorschem-
sicalsenergys(e.g.,setching)sorsevensascombinationsofsthesesenergiess(e.g.,selectroche
micalsmachining).
Thesmainsprinciplesofsallsmachiningsprocessessissprovidingssuitablesrelativesmoti
onssbetweensthescuttingstoolsandsthesworkpiecestosproducesthescharacteristicsgeomet
ry.sGenerally,stwoskindssofsrelativesmotionsmustsbesprovidedseithersbysasmachinestoo
lsorsmanually;stheysarescalledsthesprimarysmotionsandsfeedsmotion.sThesprimarysmoti
onsissthesmainsmotionsthatscausessrelativesmotionsbetweensthescuttingsedgesandswork
piece.sThesfeedsmotionsissonesthatswhensaddedstosthesprimarysmotionsleadsstosasrepeat
edsorscontinuousschipsremovalstoscreatesasmachinedssurfaceswithsthesdesiredsgeometri
cscharacteristics.sThesresultantsofsthesestwostoolsmotionssisscalledsthesresultantscuttin
gsmotion.sForsexample,sinscylindricalsturningsonslathe,sthesprimarysmotionsissthesrota
tionsofsthesworkpiecesonsitssaxis,sandsthesfeedsmotionsissthesmotionsofsthescuttingstoo
lsalongsthesaxissofsthesworkpiece.sThessecondarysprinciplesissimpartingsthesshapesofst
hescuttingstoolstosthesworkpiecesinsorderstoscreatespartsgeometry.sThestwosprinciplessa
ressometimesscombinedsinsonesoperation.sForsexample,sinsslotsmilling,sthesprimarysm
otionsissthesrotationsofsthesmillsonsitssaxis,sandsthesfeedsmotionscreatessthesslot.sThes
widthsandsshapesofsthissslotsaresdependentsonsthesgeometrysofsthescuttingstool.
ThesInternationalsOrganizationsofsStandardss(ISOs841s2001)shassrecommendedsass
ystemsofsmachinestoolsaxesstosdescribesthesmotionssofsbothsthestoolsandsworkpiecessh
ownsinsFig.s1.sThessystemswassestablishedsforsthespurposessofsprogrammingsnumeri
callyscontrolledsmachinestools.sHowever,sitscansalsosbesadoptedstosdescribesgenerals
machines(Boothroyds1975).
ThesthreescoordinatesaxessX,sY,sandsZsreferstospossibleslinearsmotionssofsthestool,sa
ndsmotionssA,sB,sandsCsreferstospossiblesrotarysmotionssofsthestoolsaboutsthosesaxes,s
respectively.s Thes Zs axiss iss arrangeds parallels tos thes axiss ofs thes spindles ofs the
Machine Tools for Machining s s s
Chapters·sSeptembers2015
DOI:s 10.1007/978-1-4471-4670-4_4
CITATIONS READS
0 33,610
2sauthors:
IrvingsPaulsGirsangsTh JaspreetsSinghsDhupias
esBluesCircle UniversitysofsAuckland
12sPUBLICATIONSs 91sCITATIONS 39sPUBLICATIONSs 324sCITATIONS
PROFILE PROFILE
Somesofsthesauthorssofsthisspublicationsaresalsosworkingsonsthesesrelatedsprojects:
WindsTurbinesElectromechanicalsModelingsViewsproject
AllscontentsfollowingsthisspageswassuploadedsbysJaspreetsSinghsDhupiasons20sJanuarys2016.
Thesusershassrequestedsenhancementsofsthesdownloadedsfile.
,Machine Tools for Machining
s s s
20
IrvingsPaulsGirsangsandsJaspreetsSinghsDhupia
Contents
Introduction ................................................................................................................................ 812
MachinesToolsOperations ........................................................................................................... 814
MachinesswithsSingle-PointsCuttingsTools ........................................................................... 814
MachinesswithsMultipointsTools ........................................................................................... 824
MachineswithsGrindingsWheels ............................................................................................ 841
MachiningsCenters ................................................................................................................ 847
MachinesToolsStructures ............................................................................................................ 849
SpindlesDrives ...................................................................................................................... 850
FeedsDrives ........................................................................................................................... 851
NumericalsControls ............................................................................................................... 853
NontraditionalsMachinesTools ................................................................................................... 855
IndustrialsRobots................................................................................................................... 855
ParallelsandsHybridsKinematicsMachinesTools ..................................................................... 859
ReconfigurablesMachinesTools ............................................................................................. 860
Summary.................................................................................................................................... 864
References.................................................................................................................................. 864
Abstract
Machiningsoperationssaresamongsthesmostsversatilesandsaccuratesmanufacturingsp
rocessessinstermssofsitsscapabilitystosproducesdiversesandscomplexsgeometricsfeat
ures.sThisschapterstakessitssfocussonsthesmachiningsprocessessutilizingssharpscutti
ngstoolsstosremovesmaterialssfromsthesworkpiecesbysshearsdeformation.s Thesmai
nsprinciplesofsthesesprocessessissprovidingsthesrelativesmotionssbetweensthescuttin
gstoolsandsthesworkpiece,swhichsissaccomplishedsthroughsmachinestools.s Thes ma
chines toolss ares discusseds ands categorizeds baseds ons thes employed
I.P.sGirsangs( )s•sJ.S.sDhupia
SchoolsofsMechanicalsandsAerospacesEngineering,sNanyangsTechnologicalsUniversity,sSingapores
e-mail:;
ⒸsSpringer-Verlags Londons 2015 811
A.Y.C.sNees(ed.),sHandbooksofsManufacturingsEngineeringsandsTechnology,s
DOIs10.1007/978-1-4471-4670-4_4
,812 I.P.sGirsangsandsJ.S.sDhupia
cuttingstools:ssingle-
pointscuttingstools,smultipointscuttingstools,sorsgrindingswheels.sMachiningscente
rs,swhichshavesflexibilitiesstosperformsvarioussmachin-
singsoperationsswithsdifferentscuttingstoolssonsmoresthansone sworkpiece,saresalsosd
iscussed.sDrivessandscontrolssaresresponsiblestosrespectivelysprovidesandsregulate
sthesmotionssofsthesmachinestoolscomponents.sThus,sindustrialsdesignssandstechno
logiessofsspindlesdrivessandsfeedsdrives,sasswellsassnumericalscontrols,saresdescribe
dsinsthisschapter.sFinally,sdifferentsmechanicalsdesigns,sinstermssofstheskinematics
mechanismstosprovidesthesrelativesmotionssbetweensthestoolsandsthesworkpiece,sh
avesbeensintroducedstosthesmanufacturingsfloors.sEachsofsthesesdesignsshasspenet
ratedstoday’ssmanufacturingsfloorsbringingscertainssuperioritysasscomparedstosthes
conventionalsmachinestools.sThisschaptersdiscussessimportantscharacteristicssofsasf
ewsofsthesesemergingsmachinestoolsdesigns,snamely,sindus-
strialsrobots,sparallelsandshybridskinematic smachinestools,sand sreconfigurablesma
chinestools.
Introduction
DevelopmentsofsmachinestoolssforsmanufacturingswasscloselysrelatedstosthesIndus-
strialsRevolution,swhichsissmarkedsbysthessuccessfulsdevelopmentsofssteamsenginesb
ysJamessWattsins1776.sWhenshesstartedsdesigningsthessteamsenginesins1763,shissprim
aryschallengeswasstosmakesthesboresofsthescylinderssufficientlysaccuratestospreventsth
essteamsfromsescapingsaroundsthespiston.sThesinitialscylinderswassmanufacturedsfro
mssheetsmetal,swhichscertainlysdidsnotsworksproperly.sThesprob-
slems wasseventuallyssolvedsbysJohnsWilkinsonswhenshesinventedsaswaterwheel-
spoweredshorizontal-
axissboringsmachinesarounds1775.sThissmachinesissoftensrecognizedsassthesfirstsmac
hinestool.
Sincesthen,smachiningsprocesssandsmachinestoolshavesalwayssbeensessentialsinspr
oductsdesignsandsmanufacturing.sSomesevensarguesthatsmachiningsissthesmostsversat
ilesandsaccuratesofsallsmanufacturingsprocessessinstermssofsitsscapabilitystosproduces
diversesgeometricsfeatures.sFurther,spartssmanufacturedsbyscasting,sforming,sorsothe
rsshapingsprocessessoftensrequiresmachiningsoperationssbeforesbeingsassembledsforst
hesfinalsproduct.sThissfinalsmachiningsoperationsissrequiredsbecausesthespartssmaysh
avesexternalsandsinternalsprofiles,sasswellsasssharpscornerssandsflatnesssthatscannotsb
esaccuratelysachievedsbysformingsandsshapingsprocesses.sAlso,sbecausesmanysengin
eeringscomponentssorspartssneedstosbesinterchangeable,sitsrequiresscontrolsofsdimensi
onalsaccuracy,swhichscansbesachievedsthroughsmachin-
singsprocess.sTherefore,scriticalschoicesshavestosbesmadesduringsproductsdesignsands
manufacturingsplanningsaboutsthesextentsofscasting,sshaping,sorsformingsagainststhese
xtentsofsmachiningstosbesdonesonsasworkpiece.
Machiningsissthesgeneralstermsusedstosdescribesthesmaterialsremovalsprocesssfrom
sasworkpiece,swhichsissaswidestopic.sInsthe sinterestsofsasfocusedsdiscussion,sthesscopes
ofsthisschaptersisslimitedstosthesprocessessusingssharpscuttingstoolsstosformsaschipsfro
msthesworkpiecesbysshearsdeformation.sThisschaptersalsosdescribessthesmachines too
lss tos performs theses machinings operations.s Besidess thes operations
, 20s MachinesToolssforsMachining 813
Fig.s1s Coordinatessystemsforsmotionssofs(a)stoolsands(b)sworkpiece
describedsinsthisschapter,sothersmechanismsscansbesappliedstosremovesmaterialsotherst
hansusingssharpscuttingstool.sThesesalternativesmechanismssmaysinvolvesthesusesofsm
echanicals(e.g.,sultrasonicsorswatersjetsmachining),sthermals(e.g.,selectricalsdis-
scharge,selectronsbeam,slasersbeam,sarc,sorsoxyfuelsmachining),selectrical,sorschem-
sicalsenergys(e.g.,setching)sorsevensascombinationsofsthesesenergiess(e.g.,selectroche
micalsmachining).
Thesmainsprinciplesofsallsmachiningsprocessessissprovidingssuitablesrelativesmoti
onssbetweensthescuttingstoolsandsthesworkpiecestosproducesthescharacteristicsgeomet
ry.sGenerally,stwoskindssofsrelativesmotionsmustsbesprovidedseithersbysasmachinestoo
lsorsmanually;stheysarescalledsthesprimarysmotionsandsfeedsmotion.sThesprimarysmoti
onsissthesmainsmotionsthatscausessrelativesmotionsbetweensthescuttingsedgesandswork
piece.sThesfeedsmotionsissonesthatswhensaddedstosthesprimarysmotionsleadsstosasrepeat
edsorscontinuousschipsremovalstoscreatesasmachinedssurfaceswithsthesdesiredsgeometri
cscharacteristics.sThesresultantsofsthesestwostoolsmotionssisscalledsthesresultantscuttin
gsmotion.sForsexample,sinscylindricalsturningsonslathe,sthesprimarysmotionsissthesrota
tionsofsthesworkpiecesonsitssaxis,sandsthesfeedsmotionsissthesmotionsofsthescuttingstoo
lsalongsthesaxissofsthesworkpiece.sThessecondarysprinciplesissimpartingsthesshapesofst
hescuttingstoolstosthesworkpiecesinsorderstoscreatespartsgeometry.sThestwosprinciplessa
ressometimesscombinedsinsonesoperation.sForsexample,sinsslotsmilling,sthesprimarysm
otionsissthesrotationsofsthesmillsonsitssaxis,sandsthesfeedsmotionscreatessthesslot.sThes
widthsandsshapesofsthissslotsaresdependentsonsthesgeometrysofsthescuttingstool.
ThesInternationalsOrganizationsofsStandardss(ISOs841s2001)shassrecommendedsass
ystemsofsmachinestoolsaxesstosdescribesthesmotionssofsbothsthestoolsandsworkpiecessh
ownsinsFig.s1.sThessystemswassestablishedsforsthespurposessofsprogrammingsnumeri
callyscontrolledsmachinestools.sHowever,sitscansalsosbesadoptedstosdescribesgenerals
machines(Boothroyds1975).
ThesthreescoordinatesaxessX,sY,sandsZsreferstospossibleslinearsmotionssofsthestool,sa
ndsmotionssA,sB,sandsCsreferstospossiblesrotarysmotionssofsthestoolsaboutsthosesaxes,s
respectively.s Thes Zs axiss iss arrangeds parallels tos thes axiss ofs thes spindles ofs the
