ENME 623 Analysis of Machining Systems

Fall 1998

Chapter 1 Introduction to Machining Systems

I. Definition of Machining Systems

II. Current Status of Machine Tools Research

II. Concept of Sensor-based Machining Operations

Chapter 2 Mathematical Modeling of Machining Systems

I. Conceptualization of Integrated Machining Systems

1.1 Three Basic Components

1.2 Inputs and Outputs

II. Mathematical Modeling

2.1 Modeling of Cutting Process

2.2 Modeling of Structural Dynamics of Machine Tool

2.3 Modeling of Feedback Mechanisms

2.4 Identification of the System Transfer Function

Chapter 3 Dynamic Analysis of Machining Systems


I. Stability Analysis

1.1 Nyquist Criterion for Nonoverlapping Systems

1.2 System Complex Frequency Method for Overlapping Systems

1.3 Method to Construct Stability Charts

1.4 Method of Mathews Equation for Intermittent Machining Systems

II. Evaluation of Tool Vibration

2.1 Deterministic Part

2.2 Stochastic Part (Concept of Micro and Macro-Cutting Mechanics)

2.2.1 Modeling of Random Excitation System

(1) Random Excitation Sources

(2) Related Issues

(3) Model of Random Excitation System

i. Population Distribution

ii. The Distribution of the mean of the samples

iii. The Correlation Coefficient Function

iv. The Geometrical Shape Function

v. The evaluation of the sample Variance

2.2.2 Experimental Methods to Estimate the Parameter Values Proposed

(1) SEM Method to Estimate

i. The Mean and Variance of the Population

ii. The Correlation Coefficient Function

(2)Microhardness Measurement Method to Estimate Microhardness
Values of the Microstructures

2.2.3 Transformation of the Random Excitation System from Hardness
Variation to Cutting Forces Variation to Equivalent Chip Load Variation

(1) Kronenberg's Cutting Force Model and Meyer's Exponent

(2) Mapping Function between Hardness Variation and Cutting Force Variation

(3) Mapping Function between Cutting Force Variation and Equivalent Chip Load Variation

2.24 Strategy to Simulate the Tool Motion, both Deterministic and Stochastic Parts.

2.3 Markov Model Approach

III. Analysis of Machining Accuracy

3.1 System Performance Index Approach

3.2 Predication through Computer Simulation

Chapter 4 Practical Applications

I. Design of Dynamometers and Sensors For On-line Monitoring

II. Design of a Smart Tool Post Structure

III. Machining of Advanced Engineering Materials

Chapter 5 Laboratory Work: CNC Machining

I. Concept of NC Machining

II. Part Programming using G-Code

III Part-making through Operating a CNC Machining Center


Email: zhang@eng.umd.edu