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brecher c machine tools production systems 2 design 2022

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Textbook in PDF format 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. Introduction 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 Application References Installation 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 Isolation References Hydraulics 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 Units References Guide 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 Elements References Transmissions 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 Gearing References Industrial 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 Results References Methods 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 measurement References Geometric 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 - References 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 Analysis References Thermoelastic 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 Displacements References The 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 Processes References Machine 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 VDMA References Acoustic 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 Aspects References Formula Directory Index

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