The CNC Handbook: Digital Manufacturing and Automation from CNC to Industry 4.0
- Length: 720 pages
- Edition: 1
- Language: English
- Publisher: Industrial Press
- Publication Date: 2021-11-15
- ISBN-10: 0831136367
- ISBN-13: 9780831136369
- Sales Rank: #5792439 (See Top 100 Books)
Digital manufacturing is everywhere. Technology advances in production engineering have reduced the “artisan skill” traditionally required in manufacturing processes and replaced it with high-precision, computer-controlled machinery. This reduces human errors and variability in output, but it does not reduce the knowledge required of the professional engineer or shop floor worker. In fact, the reverse is true. They still need to understand the fundamentals, and must acquire other important skills.
Anyone who works in machining or additive manufacturing technology must have a solid technical knowledge of CNC technology. It is important to know how the individual components work and how they affect the overall system, the quality of the products produced and the profitability of production. Professionals should be familiar with today’s machine tools and the numerous functions of CNC, electrical servo drives, tool systems, NC programming through to digital information processing and automation.
The CNC Handbook was a critically acclaimed bestseller in Germany for 30 editions, and is now available in English for the first time. This groundbreaking work introduces readers to the CNC world, and teaches practical details about how different components are applied in practice. Next, the authors explain the functions and connections of all integrated components, and clearly describe CNC and drives, tooling, flexible manufacturing systems (FMS), NC-programming, DNC, digital manufacturing, Industry 4.0 and computer integrated manufacturing (CIM). The book then covers industrial robots, additive manufacturing, energy-efficient manufacturing, simulation systems, and state-of-the-art of machine integrated measuring systems. This authoritative, heavily illustrated book is the perfect resource for the avid CNCer, but also for those who plan and program, set up, operate machinery, or are responsible for operation, maintenance and repair.
Features
- Packed with more than 800 figures, 4-color pictures, and product shots.
- Authors use their more than 150 combined years of industrial and academic experience to impart CNC knowledge.
Foreword PART 1 INTRODUCTION TO CNC TECHNOLOGY 1Historical Development of Numerical Control Production Germany after World War II Rebuilding the German Machine Tool Industry Machine Tool Industry in Eastern Germany Worldwide Changes Advancement of the German Machine Tool Industry The Japanese Influence The Crisis in Germany Causes and Effects Flexible Manufacturing Systems World Economic Crisis of 2009 Situation and Outlook Conclusion 2Milestones in the Development of Numerical Control 3What Is NC and CNC? The Path to NC Hardware Software Control Methods NC Axes Programmable Logic Controllers Interface Section Computers and NC NC Programs Programming Data Input Operation Summary Important Points to Remember PART 2 FUNCTIONS OF CNC MACHINE TOOLS 4Positional Data Input Introduction Axis Designations Closed-Loop Position Control Position Measurement Simple Diagnosis of Measurement Devices Compensations Important Points to Remember 5Switching Functions Explanations Tool Change Tool Changing at Milling Machines and Machining Centers Tool Changing on the Lathe Tool Location Coding Workpiece Change Spindle Speed Change Feed Rate Summary Important Points to Remember 6Operating Functions of Numerical Control Systems Definition Basic Functions of CNC Special Functions of CNC Systems Dynamic Collision Monitoring Integrated Safety Concepts for CNC Machines Condition Monitoring and Machine Data Collection Displays in CNC Systems Touch Operation of the CNC System Open Controls Price Consideration Advantages of Newest CNC Developments Summary Important Points to Remember 7Programmable-Logic Controllers (PLCs) Definition Origins of PLC Structure and Functions of PLCs Data Buses and Field Buses Advantages of PLCs PLC Programming and Documentation Program Program Memory PLCs, CNC Systems, and PCs in Integrated Operation Selection Criteria for PLCs Summary Comparison Tables CNC/PLC Important Points to Remember 8Effects of CNC on Machine Components Machine Configuration Machine Frames Guides Machine Enclosures Coolant Supply Chip Removal Summary Important Points to Remember PART 3 ELECTRICAL DRIVES OF CNC MACHINE TOOLS 9Drive Control for CNC Machine Tools Definition Mechanical Axis Analog Control Analog versus Digital Position Control Digital Intelligent Drive Technology Controller Types and Controlling Behavior Loop Gain and Factor Precontrol Frequency Converter Summary Important Points to Remember 10 Feed Drives for CNC Machine Tools Requirements for Feed Drives Types of Feed Drives Types of Linear Motors Advantages/Disadvantages of Linear Drives Connection of the Drives to the CNC System Encoder Summary Important Points to Remember 11 Main Spindle Drives Requirements for Main Spindle Drives Types of Main Spindle Drives Designs of Main Spindle Drives Types of Three-Phase Synchronous Motors Advantages and Disadvantages of Three-Phase Synchronous Motors Important Points to Remember 12 Dimensioning of Drives for Machine Tools Procedure Example Dimensioning of Main Spindle Drives Example Summary Important Points to Remember 13 Mechanical Layout of the Main Spindle Based on the Process Parameters Motor Selection Bearings Lubrication Machining Processes Requirements for the Main Spindle in Terms of Industry 4.0 Important Points to Remember PART 4 KINDS OF CNC MACHINES 14 CNC Machine Tools Machining Centers, Milling Machines Lathes Grinding Machines Gear-Cutting Machines Drilling Machines Sawing Machines Laser Machining Systems Punching and Nibbling Machines Tube-Bending Machines Electrical-Discharge Machines Wire EDM Electron-Beam Machines Water-Jet Cutting Machines Multitasking Machines Measuring and Testing Summary Important Points to Remember 15 Additive Manufacturing Processes Introduction Definition Process Chain Classification of Additive Manufacturing Processes Introduction to the Principal Layer Manufacturing Processes Advantages of Additive Manufacturing Summary Important Points to Remember 16 Flexible Manufacturing Systems Definition Flexible Manufacturing Cells. Flexible Manufacturing Systems Technical Characteristics of FMSs Application Criteria for FMSs Manufacturing Principles Machine Selection and Layout Workpiece Transport Systems CNC Systems Suitable for Flexible Manufacturing Host Computers in FMSs Economic Advantages of FMSs Problems and Risks in the Design of FMSs Flexibility and Complexity. Simulation of FMSs Production Planning Systems Summary Important Points to Remember 17 Industrial Robots and Handling Introduction What Is an Industrial Robot?. Structure of Industrial Robots Mechanical Elements/Kinematics Gripper or Effector CNC Systems Safe Robot Technology Programming Sensors Application Examples for Industrial Robots CNC-Robot Machining and Machine Tool Automation Robot with CNC Requirements Application Criteria for Industrial Robots Summary and Outlook Important Points to Remember 18 Energy-Efficient, Cost-Effective Fabrication Introduction What Is Energy Efficiency? Work Floor Machinery Special Case: Machining Centers Energy-Efficient NC Programs Options of the Machine Manufacturer Options for the User Reactive Power Compensation What Is Reactive Power? Summary Outlook Important Points to Remember PART 5 TOOLS IN CNC PRODUCTION 19 Tool Construction Introduction Requirements Outline of Tools Machine-Based Tool Holders Modular Tool Systems Adjustable Tools Thread Milling Custom Tools Tool Selection Important Points to Remember 20 Tool Management. Motives for Introduction Evaluation of a Tool Management System. Assessment of Solutions. Introduction of a Tool Management System Outline Integration Tool Identification Retrieving Tools Tool Classification Tool Components Complete Tools Tool Lists Operations Tool Presetting Tool Logistics Electronic Tool Identification Summary Important Points to Remember 21 Machine-Integrated Workpiece Measurements and Process Control Introduction Starting Points for Process Control Areas of Application of Workpiece and Tool Measuring Systems Workpiece Measurement Systems for Machine Tools Important Points to Remember 22 Machine-Integrated Workpiece Measurements in Series Production Introduction Bore-Measuring Heads for Shortest Measuring Times in Bore Production. Roughness-Measuring Devices for the Automated Surface Test Digilog Probe for Digital and Analog Data Acquisition Highest Productivity with Simultaneous Measurement Summary Important Points to Remember 23 Laser-Based Tool Monitoring Introduction Tool Breakage Monitoring Single-Cutting-Edge Control Measurement of HSC Tools Combined Laser Measurement Systems Summary Important Points to Remember PART 6 NC PROGRAM AND PROGRAMMING 24 The CNC Program Definitions Structure of the NC Program. Program Structure, Syntax, and Semantics Miscellaneous (M) Functions Positioning Data Preparatory (G) Functions Machining Cycles Zero Points and Reference Points Transformations Tool Corrections DXF Converter High-Level Language Programming Summary Important Points to Remember 25 Programming CNC Machines. Definition of NC Programming Programming Methods CAM-Based CNC Machining Strategies User-Friendly Graphics CNC Identical Programming Systems Selection of the Appropriate Programming System Summary Important Points to Remember 26 NC Programming Systems Introduction Changing Machining Processes Area of Application Sets the Priorities Input Data from Different Sources Scope of a Modern Computer-Aided Programming (CAP) System High-Level Data Models CAM-Oriented Geometry Manipulation High-Performance Machining Strategies Are Paramount Adaptive Processing 3D Models Offer More 3D Interfaces Innovation with Feature Technology Automation of NC Programming Tools Clamping Planning and Definition of the Sequence The Importance of Simulation Postprocessor Generated Data and Interfaces with the Machine Tools Summary Important Points to Remember 27 Manufacturing Simulations Introduction Qualitative Classification of Systems Components of a Simulation Scenario Procedure for NC Simulations Integrated Simulation Systems Fields of Application Summary Important Points to Remember PART 7 FROM COMPANY INFORMATION SYSTEMS TO INDUSTRY 4.0 28 DNC: Direct Numerical Control or Distributed Numerical Control Definition Functions of DNC Application Criteria for DNC Systems Data Communication with CNC Systems Methods for Requesting Programs DNC Systems Currently Available Network Technology for DNC Systems Advantages of Using Networks NC Program Management Advantages of DNC Operation Cost-Effectiveness of DNC Current State and Trends Summary Important Points to Remember 29 LANs: Local-Area Networks Introduction Local-Area Networks (LANs) What Is Information? Characteristics and Features of LANs Gateways and Bridges Criteria for Selecting a Suitable LAN Interfaces Summary Important Points to Remember 30 Digital Product Development and Manufacturing: From CAD and CAM to PLM Introduction Terminology and History Digital Product Development Digital Manufacturing Summary Important Points to Remember 31 Industry 4.0 Basics Core Elements of Industry 4.0 Industry 4.0 in Production MES as a Building Block of Industry 4.0 Challenges and Risks of Industry 4.0 32 Industry 4.0 in the Medium-Sized Company Requirements for Industry 4.0 Benefits of Industry 4.0 Cyber-Physical Systems (CPSs), the Internet of the Things Sixteen Case Studies about Industry 4.0 A Workday with Industry 4.0 Summary Important Points to Remember Glossary Index
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