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Hans Bernhard Kief - The CNC Handbook: Digital Manufacturing and Automation from CNC to Industry 4.0

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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 todays 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.

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THE CNC HANDBOOK THE CNC HANDBOOK Hans B Kief Helmut A Roschiwal - photo 1
THE CNC HANDBOOK THE CNC HANDBOOK Hans B Kief Helmut A Roschiwal - photo 2
THE CNC HANDBOOK
THE CNC HANDBOOK
Hans B. Kief
Helmut A. Roschiwal
Karsten Schwarz
INDUSTRIAL PRESS, INC.
Industrial Press, Inc.
Haviland Street, Suite
South Norwalk, Connecticut 06854
Phone: 203-956-5593
Toll-Free in USA: 888-528-7852
Email: info@industrialpress.com
Authors: Hans B. Kief, Helmut A. Roschiwal, and Karsten Schwarz
Title: The CNC Handbook
Library of Congress Control Number: 2019951882
by Industrial Press, Inc.
All rights reserved. Published in 2022.
Printed in the United States of America.
ISBN (print): 978-0-8311-3636-9
ISBN (ePUB): 978-0-8311-9498-7
ISBN (eMOBI): 978-0-8311-9499-4
ISBN (ePDF): 978-0-8311-9497-0
Publisher/Editorial Director: Judy Bass
Copy Editor: James Madru
Compositor: Paradigm Data Services (P) Ltd., Chandigarh
Proofreader: Claire Splan
Indexer: Claire Splan
No part of this book may be reproduced or transmitted in any form or by any means, elec- tronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without written permission from the publisher.
Limits of Liability and Disclaimer of Warranty
The author and publisher make no warranty of any kind, expressed or implied, with regard to the documentation contained in this book.
All rights reserved.
industrialpress.com
ebooks.industrialpress.com
Contents
Foreword
PART 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 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 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
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
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
Dimensioning of Drives for Machine Tools
Procedure
Example
Dimensioning of Main Spindle Drives
Example
Summary
Important Points to Remember
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 KINDS OF CNC MACHINES
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
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
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
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