Modular Design for Machine Tools ABOUT THE AUTHOR Yoshimi Ito, Dr.-Eng., C.Eng., FIET, is professor emeritus at the Tokyo Institute of Technology and past president of the Japan Society of Mechanical Engineers The author of numerous engineering research papers and books, he is currently vice president of the Engineering Academy of Japan and a visiting professor at the Kanagawa Institute of Technology Copyright © 2008 by The McGraw-Hill Companies, Inc Click here for terms of use Modular Design for Machine Tools Yoshimi Ito, Dr.-Eng., C.Eng., FIET Professor Emeritus Tokyo Institute of Technology New York Chicago San Francisco Lisbon London Madrid Mexico City Milan New Delhi San Juan Seoul Singapore Sydney Toronto Copyright © 2008 by The McGraw-Hill Companies, Inc All rights reserved Manufacturin the United States of America Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any means, or stored in a database or retrieval system, without the prior written permission of the publisher 0-07-159577-5 The material in this eBook also appears in the print version of this title: 0-07-149660-2 All trademarks are trademarks of their respective owners Rather than put a trademark symbol after every occurrence of a trademarked name, we use names in an editorial fashion only, and to the benfit of the trademark owner, with no intention of infringement of the trademark Where such designations appear in this book, they have been printed with initial caps McGraw-Hill eBooks are available at special quantity discounts to use as premiums and sales promtions, or for use in corporate training programs For more information, please contact George Hoare, Special Sales, at george_hoare@mcgraw-hill.com or (212) 904-4069 TERMS OF USE This is a copyrighted work and The McGraw-Hill Companies, Inc (“McGraw-Hill”) and its licensors reserve all rights in and to the work Use of this work is subject to these terms Except as permitted under the Copyright Act of 1976 and the right to store and retrieve one copy of the work, you may not decompile, disassemble, reverse engineer, reproduce, modify, create derivative works based upon, transmit, distribute, disseminate, sell, publish or sublicense the work or any part of it without McGraw-Hill’s prior consent You may use the work for your own noncommercial and personal use; any other use of the work is strictly prohibited Your right to use the work may be terminated if you fail to coply with these terms THE WORK IS PROVIDED “AS IS.” McGRAW-HILL AND ITS LICENSORS MAKE NO GUARANTEES OR WARRANTIES AS TO THE ACCURACY, ADEQUACY OR COMPLETENESS OF OR RESULTS TO BE OBTAINED FROM USING THE WORK, INCLUDING ANY INFORMTION THAT CAN BE ACCESSED THROUGH THE WORK VIA HYPERLINK OR OTHEWISE, AND EXPRESSLY DISCLAIM ANY WARRANTY, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE McGraw-Hill and its licensors not warrant or guarantee that the functions contained in the work will meet your requirements or that its operation will be uninterrupted or error free Neither McGraw-Hill nor its licensors shall be liable to you or anoneelse for any inaccuracy, error or omission, regardless of cause, in the work or for any damages resulting therefrom McGraw-Hill has no responsibility for the content of any information accessed through the work Under no circumstances shall McGraw-Hill and/or its licensors be liable for any indirect, incidental, special, punitive, consequential or similar damages that result from the use of or inability to use the work, even if any of them has been advised of the possibility of such damages This limitation of liability shall apply to any claim or cause whatsoever whether such claim or cause arises in contract, tort or otherwise DOI: 10.1036/0071496602 Professional Want to learn more? 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If you’d like more information about this book, its author, or related books and websites, please click here For more information about this title, click here Contents Preface ix Terminology and Abbreviations Nomenclature xix Conversion Table xxiii xiii Part Engineering Guides of Modular Design and Description Methodology of Machine Tools Chapter Basic Knowledge: What Is the Modular Design? 1.1 Definition and Overall View of Modular Design 1.2 Advantageous and Disadvantageous Aspects of Modular Design 1.3 A Firsthand View of Developing History and Representative Applications 1.3.1 Application to TL and FTL 1.3.2 Application to conventional machine tools 1.3.3 Application to NC machine tools 1.3.4 Different-kind generating modular design References Chapter Engineering Guides and Future Perspectives of Modular Design 2.1 Four Principles and Further Related Subjects 2.2 Effective Tools and Methodology for Modular Design 2.3 Classification of Modular Design Including Future Perspectives 2.3.1 Modular design being widely employed 2.3.2 Modular design in the very near future—a symptom of upheaval of new concepts 2.4 Characteristic Features of Modular Design Being Used in Machine Tools of the Most Advanced Type 2.4.1 System machines 2.4.2 Machining complex and processing complex References 11 17 20 27 40 47 54 60 63 64 72 76 78 80 86 88 102 108 v vi Contents Chapter Description of Machine Tools 3.1 Basic Knowledge about Functional and Structural Description Methods 3.2 Details of Functional Description 3.3 Details of Structural Description References Chapter Application of Machine Tool Description to Engineering Design 4.1 Application of Functional Description 4.1.1 Classification of machining centers and its application to marketability analysis 4.1.2 Analysis of machining function and its application to evaluate compatibility with production systems 4.1.3 Automated generation of concept drawing 4.1.4 Estimation of assembly accuracy in design stage 4.2 Application of Structural Description 4.2.1 Similarity evaluation of structural configuration—availability constraints of modular design 4.2.2 Variant design for structural configuration 4.2.3 Free design for structural configuration References 111 112 115 123 128 131 131 131 135 138 148 149 150 157 165 171 Part Engineering Design for Machine Tool Joints—Interfacial Structural Configuration in Modular Design Chapter Basic Knowledge of Machine Tool Joints 5.1 Classification of Machine Tool Joints 5.2 Definition of Machine Tool Joint and Representation of Joint Characteristics 5.3 External Applied Loads to Be Considered and Fundamental Factors Governing Joint Characteristics 5.4 Effects of Joint on Static and Dynamic Stiffness, and Thermal Behavior of Machine Tool as a Whole 5.5 Firsthand View of Research History References Chapter Fundamentals of Engineering Design and Characteristics of the Single Flat Joint 6.1 Quick Notes for Single Flat Joint, Determination of Mathematical Model, and Fundamental Knowledge about Engineering Design Formulas 6.2 Design Formulas for Normal Joint Stiffness and Related Research 6.2.1 Expressions for static normal joint stiffness 6.2.2 Representative researches into behavior of the single flat joint under normal loading 175 181 190 196 198 204 210 213 214 218 218 225 Contents 6.3 Design Formulas for Tangential Joint Stiffness, Related Researches, and Peculiar Behavior of Microslip 6.3.1 Expressions for static tangential joint stiffness 6.3.2 Representative researches into behavior of the static tangential joint stiffness and the microslip 6.3.3 Peculiar behavior of microslip 6.4 Design Formulas for Damping Capacity and Related Researches 6.4.1 Expressions for damping capacity 6.4.2 Representative research into dynamic behavior 6.5 Thermal Behavior of Single Flat Joint 6.6 Forerunning Research into Single Flat Joint with Local Deformation References Supplement: Theoretical Proof of Ostrovskii’s Expression Chapter Design Guides, Practices, and Firsthand View of Engineering Developments—Stationary Joints 7.1 Bolted Joint 7.1.1 Design guides and knowledge—pressure cone and reinforcement remedies from structural configuration 7.1.2 Engineering design for practices—suitable configuration of bolt pocket and arrangement of connecting bolts 7.1.3 Engineering calculation for damping capacity 7.1.4 Representative researches and their noteworthy achievements—static behavior 7.1.5 Representative researches and their noteworthy achievements—dynamic behavior 7.1.6 Representative researches and their noteworthy achievements—thermal behavior 7.2 Foundation 7.2.1 Engineering calculation for foundation 7.2.2 Stiffness of leveling block References Supplement 1: Firsthand View for Researches in Engineering Design in Consideration of Joints Supplement 2: Influences of Joints on Positioning and Assembly Accuracy Supplement References Chapter Design Guides, Practices, and Firsthand View of Engineering Developments—Sliding Joints 8.1 Slideways 8.1.1 Design knowledge—slideway materials 8.1.2 Design knowledge—keep plate and gib configurations 8.2 Linear Rolling Guideways (Linear Guide and Rolling Guideways) 8.3 Main Spindle-Bearing Systems 8.3.1 Static stiffness of rolling bearing 8.3.2 Dynamic stiffness and damping capacity of rolling bearing 8.4 Sliding Joints of Special Types 8.4.1 Screw-and-nut feed driving systems 8.4.2 Boring spindle of traveling type References vii 232 232 233 243 246 247 252 260 267 276 278 281 281 288 300 311 320 332 335 339 345 347 352 354 357 357 359 363 370 374 381 386 389 395 400 401 403 406 viii Contents Supplement: Deflection and Interface Pressure Distribution of Slideway Supplement Reference Chapter Rudimentary Engineering Knowledge about Other Joints 9.1 Joints for Light-Weighted Structures 9.1.1 Welded joint 9.1.2 Bonded joint 9.2 Taper Connection 9.3 Chucking References Appendix Measurement of Interface Pressure by Means of Ultrasonic Waves A1.1 Principle of Measurement and Its Verification A1.2 Some Applications and Perspectives in the Very Near Future References Appendix Model Testing and Theory A2.1 Model Testing and Theory for Structural Body Component A2.2 Model Testing in Consideration of Joints References Index 493 407 414 415 416 417 432 438 447 453 455 457 466 478 481 482 487 492 ... Methodology for Modular Design 2.3 Classification of Modular Design Including Future Perspectives 2.3.1 Modular design being widely employed 2.3.2 Modular design in the very near future—a symptom... the modular design of hierarchical type, which was proposed by Brankamp of Aachen and Herrmann of Langen, Germany, in 1969 Importantly, the modular design for machine tools has a long history since... McGraw -Hill nor its licensors shall be liable to you or anoneelse for any inaccuracy, error or omission, regardless of cause, in the work or for any damages resulting therefrom McGraw -Hill has