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عدد المساهمات : 19001 التقييم : 35505 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
| موضوع: كتاب Precision Manufacturing الإثنين 02 أبريل 2012, 11:51 pm | |
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أخوانى فى الله أحضرت لكم كتاب Precision Manufacturing David Dornfeld University of California at Berkeley 6195 Etcheverry Hall Berkeley, California 94720 Dae-Eun Lee Lawrence Berkeley National Laboratory Mechanical Engineering 1 Cyclotron Road Berkeley, California 94720
ويتناول الموضوعات الأتية :
TABLE OF CONTENTS 1.1 Precision engineering 1 1.2 Precision manufacturing 2 1.3 Competitive drivers of precision manufacturing 7 1.4 Historical developments in manufacturing 9 1.4.1 Background 9 1.4.2 Key drivers 13 1.4.3 Historical examples 16 1.5 Organization of this book 33 37 2.1 Background on machine design for manufacturing 37 2.2 Philosophy of precision machine design 39 41 49 3.1 Definition of terms – accuracy, repeatibility, and resolution 49 3.1.1 Accuracy 49 3.1.2 Repeatability (or precision) 53 3.1.3 Resolution 54 3.1.4 Probabilistic measure of accuracy 55 3.2 Metrology and measurement 57 Preface & Acknowledgements 2.3 Sources of error - overview II. Machine design for precision manufacturing Introduction to precision manufacturing III. Principles of measurement xvii3.3 Abbé’s principle 64 67 3.4.1 Measurement of dimension and angle 67 3.4.2 Measurement of form 73 3.4.2.1 Straightness 73 3.4.2.2 Flatness 84 3.4.2.3 Roundness 88 3.4.2.4 Other form errors 99 3.4.3 Measurement of surface roughness 99 3.4.4 Kinematic precision 110 3.5 Subsurface damage 112 121 4.1 Introduction 121 4.2 Errors due to machine elements (excluding bearings) 123 4.3 Kinematic design 128 4.3.1 Connectivity 128 4.3.2 Kinematic elements 129 4.3.3 Contact and complex support 133 4.3.4 Summary of kinematic design 142 4.4 Structural compliance 143 4.4.1 Microscale compliance 143 4.4.2 Macroscale compliance 145 4.5 Bearings and spindles 153 4.5.1 Bearings 153 4.5.2 Aerostatic bearings and spindles 163 167 167 5.2 Thermal effects in precision engineering 171 5.3 Determining the effect of temperature other than 20°C 180 5.3.1 Free and constrained bodies 181 5.3.2 Effect of spatial temperature gradients 184 5.3.3 Effect of temperature transients: soak-out time and sinusoidal response 187 viii PRECISION MANUFACTURING 5.1 Background on the thermal error problem V. Thermal errors IV. Mechanical errors 3.4 Metrology techniques5.4 Conductive, convective, and radiative heat transfer parameters 193 5.5 Specific heat sources and examples of thermal problems 196 5.6 Environmental control of precision machinery 202 5.6.1 Machine enclosures 203 5.6.2 Factory and room enclosures 204 206 5.7 Thermal effects and metrology 208 5.8 Observations 215 VI. Error mapping and error budgets 217 6.1 Introduction 217 6.2 Error mapping 218 6.3 Error budget 232 6.3.1 Definition of error budget 232 6.3.2 Error budget flow chart 233 6.3.3 Combinational rules for errors 234 239 7.1 Introduction 239 7.2 Excitations in machine tools 243 7.3 Weight deformation 246 7.4 Cutting force deformation 249 variation of the cutting force 250 7.4.1.1 Introduction and background 250 7.4.1.2 Examples for single edge cutting 254 7.4.1.3 Machine stiffness and directional orientation 256 7.4.2 Type B deformation: Deformation due to the variation of the stiffness along the tool path 263 7.4.3 Comparison of the errors from deformation types A and B 267 272 7.6 Self-excited vibrations (chatter) 273 7.6.1 Introduction 273 7.6.2 Basic stability; effect of structural dynamics 278 TABLE OF CONTENTS ix 7.4.1 Type A deformation: Deformation due to the 7.5 Forced vibrations VII. Error due to compliance and vibration 5.6.3 Machine treatment without enclosures7.6.3 Variation of spindle speed and stability lobes 288 7.7 Advanced analysis 292 VIII. Sensors for precision manufacturing 295 295 8.1.1 The relevance of precision manufacturing and the need for in-process monitoring and control 295 precision manufacturing 297 8.2 Overview of sensors in manufacturing 300 8.2.1 Introduction 300 303 8.3 New developments in signal and information processing for tool condition monitoring 308 8.3.1 Introduction 308 8.3.2 Intelligent sensors 311 8.3.3 Implementation strategies 314 8.3.4 Multisensor approaches 316 8.3.5 Sensors for high speed machining 317 8.4 Acoustic emission in manufacturing 320 8.4.1 Background 320 8.4.2 Acoustic emission sources-diagnostics 322 8.4.3 Acoustic emission sources-process monitoring 323 8.4.4 Acoustic emission in machining 325 8.5 Signal processing, feature extraction and sensor fusion 334 8.5.1 Introduction 334 8.5.2 Intelligent sensor defined 337 8.5.3 Sensor fusion defined 338 8.5.4 Fusion methodologies 339 8.5.5 Neural networks 341 8.6 Applications of signal processing and sensor fusion 349 8.6.1 Introduction 349 8.6.2 Tool wear detection using time series analysis of acoustic emission 350 8.1 Introduction 8.2.2 Sensor systems for process monitoring x PRECISION MANUFACTURING 8.1.2 Requirements for sensor technology for8.6.2.1 Time series analysis 351 8.6.2.2 Experimental evaluation 355 8.7 Sensor integration using neural networks for intelligent tool condition monitoring 358 8.7.1 Use of multiple sensors 360 8.7.2 Experimental evaluation 363 8.8. The need for engineering models to design and predict the performance of in-process sensors 369 8.9 Basic sensor classification and new sensing technologies 372 8.9.1 Introduction 372 8.9.2 Basic sensor types 8.9.2.1 Mechanical sensors 8.9.2.2 Thermal sensors 380 8.9.2.3 Electrical sensors 382 8.9.2.4 Magnetic sensors 382 8.9.2.5 Radiant sensors 383 8.9.2.6 Chemical sensors 383 8.10 Applications of sensors in precision manufacturing 384 8.10.1 AE-based monitoring of grinding 384 wheel condition monitoring 385 8.10.1.2 Grinding wheel topographical mapping 387 8.10.1.3 Wheel wear mechanism 389 8.10.1.4 AE-based monitoring of face milling 390 8.10.2 AE-based monitoring of chemical mechanical planarization 393 8.10.2.1 Monitoring of abrasive process parameters 395 8.10.2.2 Precision scribing of CMP-treated wafers 398 8.10.2.3 AE-based endpoint detection for CMP 401 8.10.2.4 AE monitoring of surface chemical reactions for copper CMP 403 TABLE OF CONTENTS xi 377 377 wheel dressing 8.10.1.1 Fast AE RMS analysis for8.10.2.5 AE characteristics of oxidation and dissolution in copper CMP 411 416 Turning of Single crystal copper 418 8.10.2.8 Monitoring of ultraprecision turning of polycrystalline copper 421 8.11 Summary 422 IX. Process planning for precision manufacturing 425 9.1 Manufacturing system characteristics 425 9.2 Process planning basics 435 9.3 Process capability 438 9.3.1 Background 438 9.3.2 Process capability defined 440 9.4 C p as a planning metric 444 9.5 Legacy-system integration for precision manufacturing 451 9.6 Future integration for precision manufacturing process planning 452 X. Precision machining processes 455 10.1 Introduction 455 10.2 Influence of machining parameters, work material, and tool geometry 462 10.2.1 Influence of uncut chip thickness 462 10.2.2 Machining brittle materials 465 472 10.3 Process operating conditions 478 10.4 Precision mfg. processes-diamond turning/milling 482 10.4.1 Introduction 482 10.4.2 Machine tool design 484 10.4.3 Tool design and alignment 491 10.4.4 Chip formation and process mechanics 496 10.5 Abrasive processes – fixed and loose 505 10.5.1 Fixed abrasive processes 505 8.10.2.6 Monitoring of precision scribing 8.10.2.7 Monitoring of ultraprecision xii PRECISION MANUFACTURING directionality 10.2.3 Effects of work material crystallography/10.5.1.1 Material removal mechanisms 505 10.5.1.2 Grinding forces, power and specific energy 512 and process time constant 517 10.5.1.4 Nanogrinding 520 10.5.2 Loose abrasive processes 521 10.5.2.1 Polishing and lapping 522 10.5.2.2 Chemical mechanical 532 10.5.2.3 Process modeling in CMP 540 10.6 Non-traditional processes 551 555 11.1 Introduction 555 559 11.2.1 Introduction 559 11.2.2 So, what are they anyway and how are they made? 561 11.2.2.1 Microfabrication: background and overview 561 11.2.2.2 Lithography 564 570 11.4 Nanotechnology 572 11.4.1 Background and definitions 572 11.4.2 Nanostructured materials 576 11.4.3 Nanofabrication techniques 578 11.4.3.1 E-beam and nano-imprint Fabrication 11.4.3.2.1 Quantum structure 11.4.3.2.2 Quantum structure nanofabrication using strain-induced TABLE OF CONTENTS xiii 11.2 Basic semiconductor device manufacturing nanofabrication using epitaxy on patterned substrates self-assembly XI. Precision manufacturing applications and challe nges 10.5.1.3 Grinding stiffness, contact stiffness planarization (CMP) 11.3 Applications of semiconductor manufacturing – MEMS 11.4.3.2 Epitaxy and strain engineering 11.6 Micro-machining and small scale defects 604 11.6.3 Modeling 611 11.6.3.1 Finite element modeling 613 11.6.3.2 Molecular dynamics 615 11.6.3.3 Multiscale modeling 619 11.6.3.4 Mechanistic modeling 620 11.6.4 Workpiece and design issues 622 622 11.6.4.2 Creation of micropattern and microstructure 625 11.6.4.3 Creation of 3-dimensional 630 11.6.4.4 Ultrasonic vibration assisted micromachining 631 11.6.5 Micro-tools 633 11.6.6 Cutting fluid 638 11.6.7 Metrology in micromachining 640 11.6.8 Conclusion and outlook 644 in precision components 646 647 11.7.2 Process-based solutions 651 11.7.2.1 Milling 652 11.7.2.2 Drilling 654 11.7.3 Examples of application of burr minimization strategies 657 11.7.3.1 Tool path planning in milling 657 11.7.3.2 Burr control chart 660 11.7.3.3 Integrated process planning and burr minimization 661 11.7.4 Summary and conclusions 662 xiv PRECISION MANUFACTURING 11.4.3.3 Scanned probe techniques 11.4.4 Self-assembly 11.5 MEMS and nanotechnology applications shapes 11.6.4.1 Micromolding 11.6.1 Introduction 11.5.1 Nanotechnology applications 11.6.2 Surface and edge finish 11.7 Burrs – preventing and minimizing burr formation 11.7.1 Introduction and backgroundXII. Future of precision manufacturing 665 12.1 Introduction 665 666 12.3 Sustainable design/environmentally conscious design and manufacturing 669 12.3.1 Technologies for sustainable manufacturing 670 671 12.3.3 Sustainable manufacturing or “does green = sustainable?” 676 12.3.4 Manufacturing technology wedges 678 12.3.5 Examples of wedge technology application areas for manufacturing 680 12.3.5.1 Consumable use in machining 681 12.3.5.2 Energy use in nanoscale manufacturing 685 12.4 Environmentally conscious design of precision 12.4.1 Sustainability budgets 694 12.4.2 Constructing the sustainability budget 696 12.5 Summary comments/conclusion 701 Index 765 TABLE OF CONTENTS xv 12.2 The manufacturing pipeline 12.3.2 Green manufacturing pipeline machines References
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Admin مدير المنتدى
عدد المساهمات : 19001 التقييم : 35505 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
| موضوع: رد: كتاب Precision Manufacturing الخميس 01 نوفمبر 2012, 9:18 pm | |
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