本书重点介绍了金属切削过程力学、机床动力学及振动、进给驱动设计和控制、CNC设计原理、传感器辅助加工和数控编程技术等知识。从切削过程力学的基本原理开始，深度讨论了振动及颤振问题 ；也讨论了数控编程和计算机辅助设计/计算机辅助制造(CAD/CAM)技术。文中还详细介绍了驱动执行机构、反馈传感器的选择、进给驱动系统的建模与控制、轨迹实时生成和插补算法的设计、面向数控系统的误差分析等。每一章都包括从企业实际、设计项目和工作问题中筛选的案例。 本书特别适合高年级本科生和研究生，以及研发工程师阅读，将在这本书中找到一个清楚和彻底的方式来学习金属切削力学的工程原理、机床振动、数控系统设计、传感器辅助加工，以及CAD/CAM技术等。

制造业是我国国民经济的支柱产业，也是我国经济增长的主导部门和经济转型的基础。我国正面临着从制造业大国向制造业强国转变的关键时期，用先进制造技术振兴制造业，提升自主研发能力，树立“中国制造”、“中国创造”、“中国智造”的品牌是迫在眉睫的任务。 切削加工是机械制造中最基本的加工方法之一，它是利用刀具切除被加工对象上的多余材料，从而得到形状、精度和表面质量都符合预定要求的表面。“工欲善其事必先利其器”，选择合理的刀具及切削参数进行切削加工是保证加工效率和加工质量的重要要素。影响切削加工效率的因素很多，如切削参数选择、工艺过程设计、工艺系统设计和生产管理等，但切削参数的选择是制约加工效率提高的最主要因素。 基于切削加工过程的建模和仿真旨在通过建立适当的模型，通过仿真结果来研究切削加工参数对不易观察到的切削现象的影响，从而更加深入地了解切削加工机理和评判选择该切削参数的合理性。加工过程仿真含几何仿真和物理仿真（主要是动力学仿真），然而前者只能解决干涉验证的问题，却无法对直接影响加工效率和质量的各种物理因素（如切削力，振动，变形、温度等）提供必要的仿真和预测功能。随着企业对生产加工过程高效率、高精度的要求，单纯的几何仿真技术已经不能满足现代生产的需要。在实际应用中，铣削力、振动和变形等因素已经成为直接影响加工过程优劣的关键。基于加工过程的动力学仿真技术是在几何仿真的基础上，从动力学的角度对整个加工过程中的各种物理量、物理因素进行建模、仿真分析。从而在实际加工前预测出不同切削参数与物理量之间的相互关系，预先对加工质量进行评估。 欧美等西方发达国家对数控加工领域内的切削过程仿真优化技术进行了较早且较为深入的理论研究和实际应用，具有较高的技术水平，其主要研究成果已经成为相应的商业化应用软件。同时，作为现代先进制造技术学科领域内的一个研究方向，也有必要对加工过程动力学仿真优化技术进行深入、系统的研究。因此着眼于加工过程动力学建模仿真研究具有重要的理论价值和创新意义。 本人自1996年始至今，一直从事数控编程、数控加工技术、数控机床等方面的教学及科研工作，2003年，本人于南京航空航天大学攻读博士学位期间有幸阅读了2002年由化学工业出版社出版的《数控技术与制造自动化》（罗学科翻译）及其原著（Yusuf Altintas编著），以及后来2008年南京航空航天大学博士后流动站学习以及科研期间，多次关注Yusuf Altintas教授所在团队发表的论文和科研工作，特别是2011年参加的在北京航空航天大学由刘强教授主持的学术研讨会期间，亲自聆听了Yusuf Altintas的学术报告。在2013年1月至2014年2月，本人在加拿大英属哥伦比亚大学（University of British Columbia，简称UBC）的制造自动化实验室（Manufacturing Automation Laboratory，简称MAL）访学1年多，有幸师从于国际制造自动化领域知名学者Yusuf Altintas教授，Yusuf Altintas教授现任加拿大皇家科学院院士（RSC）、国际生产工程学会（CIRP）主席、加拿大工程院院士、美国机械工程师学会（ASME）和国际制造工程师学会（SME）会士，加拿大英属哥伦比亚大学（UBC）机械工程系终生教授。Yusuf Altintas教授是享誉世界的制造领域著名专家，主要研究方向为金属切削、机床振动、控制和虚拟加工等，其专著《Manufacturing Automation-Metal Cutting Mechanics,Machine Tool Vibrations, and CNC Design》（第2版）被广泛使用。他领导的实验室开发了先进加工过程仿真工具（CUT*PRO）、虚拟加工过程仿真工具（MACH*PRO）以及开放式模块化数控加工系统（Virtual CNC），这些产品被全球机械加工领域超过200家的公司和研究机构使用。 该书重点介绍了金属切削过程力学、机床动力学及振动、进给驱动设计和控制、CNC设计原理、传感器辅助加工和数控编程技术的等知识。本书基于120多篇期刊文章和60多篇反映作者工程、研究和教学经验的研究论文。 这本书的结构主要如下。 第一章为绪论；第二章介绍了金属切削过程力学的基本理论及原理；第三章讨论了切削加工过程中的静态变形和振动；第四章分别从频率域和离散时域两个方面介绍了正交切削和斜向切削的颤振理论；第五章介绍了数控技术及其操作和编程原理；第六章介绍了CNC系统设计的基本原理，详细介绍了进给伺服机构的数学模型。第七章介绍了传感器辅助加工，机床上安装有多种传感器，可以测量机械加工过程中的力、振动、温度和声音等。本书论述了金属切削的科学原理及其在解决制造中遇到的问题地实际应用。数学、物理、计算机、仪器仪表等学科被认为是分析或设计机床和制造过程的集成工具。 本书从切削过程力学的基本原理开始，深度讨论了振动及颤振问题；也讨论了数控编程和计算机辅助设计/计算机辅助制造(CAD/CAM)技术。文中还详细介绍了驱动执行机构、反馈传感器的选择、进给驱动系统的建模与控制、轨迹实时生成和插补算法的设计、面向数控系统的误差分析等。每一章都包括从企业实际、设计项目和工作问题中筛选的案例。 本书特别适合于高级本科生和研究生，以及研发工程师，将在这本书中找到一个清楚和彻底的方式来学习金属切削力学的工程原理，机床振动，数控系统设计，传感器辅助加工，以及CAD/CAM技术等等。 方喜峰

CHAPTER ONE　INTRODUCTION?............................................................................................1 CHAPTER TWO　MECHANICS OF METAL CUTTING?...............................................4 2.1　Introduction?..................................................................................................................................4 2.2　Mechanics of Orthogonal Cutting?.....................................................................................4 2.3　Mechanistic Modeling of Cutting Forces?....................................................................15 2.4　Theoretical Prediction of Shear Angle?..........................................................................18 2.5　Mechanics of Oblique Cutting?..........................................................................................19 2.5.1　Oblique?Cutting?Geometry?..................................................................................................19 2.5.2　Solution?of?Oblique?Cutting?Parameters?..........................................................................21 2.5.3　Prediction?of?Cutting?Forces?...............................................................................................25 2.6　Mechanics of Turning Processes?......................................................................................27 2.7　Mechanics of Milling Processes?........................................................................................35 2.7.1　Mechanics?of?Helical?End?Mills?........................................................................................41 2.8　Analytical Modeling of End Milling Forces?...............................................................43 2.8.1　Mechanistic?Identification?of?Cutting?Constants?in?Milling?.........................................46 2.9　Mechanics of Drilling?............................................................................................................47 2.10　Tool Wear and Tool Breakage.........................................................................................54 2.10.1　Tool?Wear?.............................................................................................................................56 2.10.2　Tool?Breakage?.....................................................................................................................61 2.11　Problems?....................................................................................................................................62 CHAPTER THREE　STRUCTURAL DYNAMICS OF MACHINES?...................66 3.1　Introduction?...............................................................................................................................66 3.2　Machine Tool Structures......................................................................................................66 3.3　Dimensional Form Errors in Machining?.....................................................................68 3.3.1　Form?Errors?in?Cylindrical?Turning?..................................................................................68 3.3.2　Boring?Bar?..............................................................................................................................70 3.3.3　Form?Errors?in?End?Milling?................................................................................................71 3.4　Structural Vibrations in Machining...............................................................................74 3.4.1　Fundamentals?of?Free?and?Forced?Vibrations?..................................................................75 3.4.2　Oriented?Frequency?Response?Function...........................................................................82 3.4.3　Design?and?Measurement?Coordinate?Systems?...............................................................833.4.4　Analytical?Modal?Analysis?for?Multi–Degree-of-Freedom?Systems?..........................85 3.4.5　Relative?Frequency?Response?Function?between?Tool?and?Workpiece?......................90 3.5　Modal Testing of Machine Structures?...........................................................................92 3.5.1　Theory?of?Frequency?Response?Testing?...........................................................................92 3.5.2　Experimental?Procedures?in?Modal?Testing?.....................................................................97 3.6　Experimental Modal Analysis for Multi–Degree-of-Freedom Systems?........98 3.7　Identification of Modal Parameters?.............................................................................109 3.7.1　Global?Nonlinear?Optimization?of?Modal?Parameter?Identification?.........................113 3.8　Receptance Coupling of End Mills to Spindle-Tool Holder Assembly?........115 3.8.1　Experimental?Procedure?....................................................................................................118 3.9　Problems?....................................................................................................................................120 CHAPTER FOUR　MACHINE TOOL VIBRATIONS?.................................................125 4.1　Introduction?.............................................................................................................................125 4.2　Stability of Regenerative Chatter Vibrations in Orthogonal Cutting?.........126 4.2.1　Stability?of?Orthogonal?Cutting.......................................................................................126 4.2.2　Dimensionless?Analysis?of?Stability?Lobes?in?Orthogonal?Cutting..........................132 4.2.3　Chatter?Stability?of?Orthogonal?Cutting?with?Process?Damping?..............................135 4.3　Chatter Stability of Turning Operations?...................................................................139 4.4　Chatter Stability of Turning Systems with Process Damping?.........................142 4.4.1　Metal?Cutting?Forces?.........................................................................................................144 4.4.2　Process?Damping?Gains?Contributed?by?Flank?Wear?..................................................145 4.4.3　Stability?Analysis?...............................................................................................................147 4.5　Experimental Validation?....................................................................................................148 4.6　Analytical Prediction of Chatter Vibrations in Milling?......................................149 4.6.1　Dynamic?Milling?Model?...................................................................................................149 4.6.2　Zero-Order?Solution?of?Chatter?Stability?in?Milling?...................................................154 4.6.3　Multi-Frequency?Solution?of?Chatter?Stability?in?Milling?.........................................160 4.7　Chatter Stability of Drilling Operations?....................................................................172 4.7.1　Dynamic?Drilling?Force?Model?.......................................................................................173 4.8　Frequency Domain Solution of Drilling Stability?..................................................176 4.9　Semidiscrete Time Domain Solution of Chatter Stability?.................................178 4.9.1　Orthogonal?Cutting?............................................................................................................178 4.9.2　Discrete?Time?Domain?Stability?Solution?in?Milling?..................................................182 4.10　Problems..................................................................................................................................186 CHAPTER FIVE　TECHNOLOGY OF MANUFACTURING AUTOMATION?.......191 5.1　Introduction?.............................................................................................................................191 5.2　Computer Numerically Controlled Unit?....................................................................191 5.2.1　Organization?of?a?CNC?Unit?............................................................................................191 5.2.2　CNC?Executive...................................................................................................................193 5.2.3　CNC?Machine?Tool?Axis?Conventions?..........................................................................193 5.2.4　NC?Part?Program?Structure?..............................................................................................193 5.2.5　Main?Preparatory?Functions?............................................................................................196 5.3　Computer-Assisted NC Part Programming?.............................................................201 5.3.1　Basics?of?Analytical?Geometry........................................................................................201 5.3.2　APT?Part?Programming?Language?.................................................................................206 5.4　Trajectory Generation for Computer-Controlled Machines?...........................211 5.4.1　Interpolation?with?Constant?Displacement....................................................................212 5.4.2　Acceleration-Limited?Velocity?Profile?Generation?with?Constant?Interpolation?Period?...216 5.4.3　Jerk-Limited?Velocity?Profile?Generation?.....................................................................220 5.5　Real-Time Interpolation Methods?................................................................................229 5.5.1　Linear?Interpolation?Algorithm?.......................................................................................230 5.5.2　Circular?Interpolation?Algorithm?....................................................................................234 5.5.3　Quintic?Spline?Interpolation?within?CNC?Systems?.....................................................239 5.6　Problems?....................................................................................................................................245 CHAPTER SIX　DESIGN AND ANALYSIS OF CNC SYSTEMS?......................250 6.1　Introduction?.............................................................................................................................250 6.2　Machine Tool Drives?............................................................................................................250 6.2.1　Mechanical?Components?and?Torque?Requirements...................................................251 6.2.2　Feedback?Devices?..............................................................................................................256 6.2.3　Electrical?Drives.................................................................................................................257 6.2.4　Permanent?Magnet?Armature-Controlled?dc?Motors?..................................................258 6.2.5　Position?Control?Loop?.......................................................................................................263 6.3　Transfer Function of the Position Loop?.....................................................................264 6.4　State Space Model of Feed Drive Control Systems?..............................................268 6.5　Sliding Mode Controller?....................................................................................................281 6.6　Active Damping of Feed Drives?......................................................................................285 6.7　Design of an Electrohydraulic CNC Press Brake?..................................................293 6.7.1　Hydraulic?Press?Brake?System?........................................................................................293 6.7.2　Dynamic?Model?of?Hydraulic?Actuator?Module?..........................................................296 6.7.3　Identification?of?Electrohydraulic?Drive?Dynamics?for?Computer?Control?............299 6.7.4　Digital?Position?Control?System?Design?.......................................................................301 6.8　Problems?....................................................................................................................................307 CHAPTER SEVEN　SENSOR-ASSISTED MACHINING?......................................313 7.1　Introduction?.............................................................................................................................313 7.2　Intelligent Machining Module?........................................................................................313 7.2.1　Hardware?Architecture?......................................................................................................314 7.2.2　Software?Architecture?.......................................................................................................315 7.2.3　Intelligent?Machining?Application?..................................................................................316 7.3　Adaptive Control of Peak Forces in Milling?............................................................317 7.3.1　Introduction?.........................................................................................................................317 7.3.2　Discrete?Transfer?Function?of?the?Milling?Process?System?.......................................319 7.3.3　Pole-Placement?Control?Algorithm?................................................................................321 7.3.4　Adaptive?Generalized?Predictive?Control?of?Milling?Process?...................................325 7.3.5　In-Process?Detection?of?Tool?Breakage?.........................................................................330 7.3.6　Chatter?Detection?and?Suppression?................................................................................333 7.4　Intelligent Pocketing with the IMM System?............................................................334 7.5　Problems?....................................................................................................................................336 APPENDIX A　LAPLACE AND z TRANSFORMS?....................................................341 PPENDIX B　 OFF-LINE AND ON-LINE PARAMETER ESTIMATION WITH LEAST SQUARES?...........................................................................................353 Bibliography?.........................................................................................................................................357 Index?......................................................................................................................................................363