Multimedia Attachment to the Book Manufacturing Technologies for Machines of the Future Multimedia Attachment to the Book Manufacturing Technologies.

Multimedia Attachment to the Multimedia Attachment to the BookBook

““Manufacturing Manufacturing Technologies for Technologies for

Machines of the Future”Machines of the Future”

Multimedia Attachment to the Multimedia Attachment to the BookBook

““Manufacturing Manufacturing Technologies for Technologies for

Machines of the Future”Machines of the Future”

EXIT

Prof. Pollmann W., Head of Editorial Board, Vice President Research, Materials andProduction DaimlerChrysler AG, Germany

Prof. Pollmann W., Head of Editorial Board, Vice President Research, Materials andProduction DaimlerChrysler AG, Germany

Academician, Prof. Frolow K. V., Director of the Mechanical EngineeringResearch Institute, Russian Academy of Sciences, Russia

Academician, Prof. Frolow K. V., Director of the Mechanical EngineeringResearch Institute, Russian Academy of Sciences, Russia

Prof. Dr. Sc. Dashchenko A. I., Head of Dept., Moscow State Technical University ”MAMI”, Russia

Prof. Dr. Sc. Dashchenko A. I., Head of Dept., Moscow State Technical University ”MAMI”, Russia

Mr. Inaba H., Senior Vice-President of ”Fanuc” Ltd, Japan Mr. Inaba H., Senior Vice-President of ”Fanuc” Ltd, Japan

Prof. Dr.-Eng. Santochi M., Head of Section, University of Pisa, Italy Prof. Dr.-Eng. Santochi M., Head of Section, University of Pisa, Italy

Prof. Dr.-Eng. Rehsteiner F., Head of the Institute of Machine Tools and Manufacturing, Zurich University, Switzerland

Prof. Dr.-Eng. Rehsteiner F., Head of the Institute of Machine Tools and Manufacturing, Zurich University, Switzerland

Prof. Dr-Eng. habil. Peklenik J., Head of Department, University of Ljubljana, Slovenia

Prof. Dr-Eng. habil. Peklenik J., Head of Department, University of Ljubljana, Slovenia

Editorial Board of the Book

Manufacturing Manufacturing Technologies Technologies

for Machines of for Machines of the Futurethe Future

Manufacturing Manufacturing Technologies Technologies

for Machines of for Machines of the Futurethe Future Prof. W.

Pollmann

WorkgroupWorkgroup1. Prof. Dr. Sc. A.I. Dashchenko, Moscow State Technical University <<MAMI>>, Russia

2. Mr. W. Samlowski, DaimlerChrysler AG, Germany

3. Prof. Dr. Sc. L.I. Volchkevich, Bauman TU, Russia

4. Prof. Dr. Sc. E.G. Nachapetjan, Mechanical Engineering Research Institute, Russian Academy of Sciences, Russia

5. Dr. O.A. Dashchenko, DaimlerChrysler AG, Russia

6. Mr. H. Grosser, Fraunhofer Gesellschaft, Germany

We thank the following companies for the permission to use their multimedia materials:

- 3D Systems, USA

- Kuka Roboter GmbH, Germany

- APS engineering, Germany

- Hüller Hille, GermanyCross Hüller

- Heinz-Nixdorf Institute, Germany

- University of Pisa, Italy

- DaimlerChrysler AG, Germany

- Heidelberger Druckmaschinen, Germany

- Fanuc Ltd, Japan

- Autoplant ZIL, Russia

- MSTU <<MAMI>>, Russia

- IFW University of Hannover, Germany

Multimedia Designers:

Dr. Dudin E., NIITAvtoprom, Russia

Dr. Dashchenko O., DaimlerChrysler AG, Russia

Part 1. Global Aspects of Manufacturing

Part 2. Trends and Developments of Advanced Manufacturing: Scientific Basis

Part 3. Trends and Developments of Advanced Manufacturing: Examples of Real Implementation

Part 4. Advanced Manufacturing Equipment

Part 5. Future Trends

Contents

Chapter 1. The Role of Mechanical Engineering in the 21st CenturyK.V. Frolov

Chapter 2. Globalisation of production:Consequences of Product Design and TechnologyF. H. Rehsteiner

Chapter 3. Fractal Company – a Revolution in Corporate CultureH. J. Warnecke

Chapter 4. Adaptable Production StructuresE. Westkaemper

Chapter 5. Life Cycle Engineering S. K. Ong, A. Y. C. Nee

Part 1

Chapter 6. Fundamental Points of Mechanical Engineering A. M. Dalsci, A. S. Vasiliev

Chapter 7. High-speed Machining H. Schulz

Chapter 8. Aspects of Manufacturing Systems’ Integration A. I. Dashchenko, W. Pollmann, O. A. Dashchenko

Chapter 9. CAPP systems for Machining, Assembly and Disassembly Operations M. Santochi

Chapter 10. Modeling of Machine Tools and Assembly Systems A. I. Dashchenko, W. Pollmann, O. A. Dashchenko

Chapter 11. Cybernethic Structures, Networks and Adaptive Control of Work Systems in Manufacturing

J. Peklenik

Part 2

Chapter 12. Rapid Prototyping (RP) in Manufacturing F. H. Rehsteiner

Chapter 13. Challenges in Electronic Production K. Feldmann

Chapter 14. Electronic Vacuum Technologies L. I. Volchkevich, Y. I. Panfilov

Chapter 15. New Solid-state Lasers and their Application Potentials H. Hügel

Chapter 16. New Information Technologies in Industrial Activity of the Enterprises (IAE)

R. Anderl

Chapter 17. Modeling of Manufacturing and Technological Processes in CIM V. F. Gornev, V. V. Emelyanov, S. I. Iassinovski

Part 3

Chapter 18. New Machine Tools and Systems M. Mandelli, T. Nagao, Y. Hatamura, M. Mitsuishi, M. Nakao,

F. Rehsteiner

Chapter 19. Reconfigurable Manufacturing Systems Y. Koren, U. Heisel, F. Jovane, T. Moriwaki, G. Pritschow,

G. Ulsoy, H. Van Brussel

Chapter 20. Robot Technology R. D. Schraft

Chapter 21. Methods for Nondestructive Testing and Diagnostics of Automatic Equipment and Technological Systems of Machines

N. N. Kluev, E. G. Nachapetjan, V. V. Sherbakov

Part 4

Chapter 22. Prospects of Technologies Development H. Inaba

Chapter 23. Perspectives of Innovative Technologies in Manufacturing J. Gausemeier

Part 5

Chapter 1

The role of mechanical engineering in the XXIst century

The present state of engineering technologies on a global scale reflects primarily the progress made during the XXth century. Astonishing results and successes have been achieved in many respects, but there is also evidence of a growing number of negative by-products.

Up to now progress in Mechanical Engineering has concentrated mainly on developing and improving the scientific basis and also on new design principles for yet more powerful and capable machinery and machine systems. The technical disciplines concerned most, are the structural, kinematic and dynamic analysis and synthesis of machines and machine systems for improved performance, safety aspects, tribology with special emphasis on friction and wear and improving machine resistance to the latter; understanding and avoiding the effects of vibrations and noise on people and on machinery, and, generally, improving the level of comfort and well being of the operators.

K.V. Frolov

To see CV click on the photo

Chapter 1

The role of mechanical engineering in the XXIst century

Konstantin FROLOV, Prof., Dr. Sc. (tech.), academician, vice-president of the USSR Academy of Sciences (1985-1992) and Russian Academy of Sciences (1992-1996) is an outstanding Russian scientist in the field of mechanical engineering, author of over 30 books and 800 papers, a founder of new scientific branches in biomechanics, nonlinear dynamics and safety of industrial objects. He achieved the highest Russian honors: several State Prizes, Government Awards (Gold Star of Labour Hero) and many orders and medals of the Russian Federation.

His work is well-known in America, Europe, Japan and other countries. He is an honorable member of the American Society of Mechanical Engineering (ASME), the Swedish Royal Engineering Academy, the National Academy of Engineering (USA), the Royal Academy of Engineering (Great Britain) and of seven other National Academies, some of which have awarded him with Golden Medals for significant contribution in the Mechanical Engineering Sciences.

K.V. Frolov

Chapter 2

Globalisation of production:demands on products’ construction and technology

F. H. Rehsteiner

In this chapter mostly the position of the manufacturer who is fully responsible for this product (the main contractor) is presented. The viewpoint of those carrying out the manufacturing, e.g., under subcontract, and of others interested in globalized production such as politicians and banks is not considered.

Fritz REHSTEINER, Prof., PhD., Dipl.-Eng., Act. Member of CIRP, Ass. Fellow AIAA Studies was during 9 years the Head of the Institute of Machine Tools and Manufacturing (IWF) at the Swiss Federal Institute of Technology (ETH), Zurich.

His Research Interests are:

• Machine tools, primarily milling machines with special attention to parallel kinematics machines (PKM)• Cutting processes• Aerodynamics• Astronomy

Prof. Rehsteiner is the author of approximately 20 publications in these research fields.

F. H. Rehsteiner

Chapter 3

Fractal company – a revolution in corporate culture

To a large degree, it is possible to draw a parallel in the field of flexible production. The vision of large, highly complex and extremely flexible automatic production systems has not yet become reality. On the other hand, it is now commonplace within the metal processing industry for processing centres to employ an automated, operator-free exchange of tools and working materials during the third shift. This trend is reflected, too, in a drastic reduction in demand for consultancy services in recent years. The know-how formerly sought from external sources during the introduction of such systems, now constitutes part of standard expertise in engineering technology, even within a large number of medium-sized companies.

H. J. Warnecke

H. J. Warnecke

Hans-Juergen WARNECKE, Prof., Dr.-Eng., Dr. h. c. mult., President of the Fraunhofer Gesellschaft was born in 1934. He studied mechanical engineering at the ”Technische Hochschule” in Brunswick and was employed in engineering research. He became a Doctor of Engineering in 1963.

Becoming a Professor in 197,1 he occupied the Chair of Industrial Manufacturing and Factory Operation at the University of Stuttgart, and also became head of the Fraunhofer Institute for Manufacturing Engineering and Automation IPA.

Since 1993 Prof. Warnecke has been the President of the Fraunhofer Gesellschaft (Association for the Promotion of Applied Research) with its headquarters in Munich and from January 1995 until January 1998 - the President of the Association of German Engineers VDI. He has got numerous honours, including honorary doctorates from the Universities of Magdeburg, Ljubljana and Timisoara and the Distinguished

Service Cross, 1st class, of the Federal Republic of Germany.

Chapter 4

Adaptable production structures

Companies in processing industries operate today in a turbulent environment. This is mainly caused by technology, the globalization of markets and the permanent change in supply and demand. Effective survival strategies can only be developed if structures are adapted constantly.

In this chapter strategies and methods contributing towards new dynamics will be discussed. The starting point of this article is the assessment of the adaptability of companies in this turbulent environment. The theme “adaptable production structures” is the subject of a long-term interdisciplinary fundamental research project at the University of Stuttgart in Germany, with the assistance of economical, technical and biotechnological institutes.

E. Westkaemper

E. Westkaemper

Engelbert WESTKAEMPER, Univ.-Prof., Dr.-Eng., Prof. E.h., Dr.-Eng., E.h. Dr. h.c., since 1995 Director of the Institut für Industrielle Fertigung und Fabrikbetrieb (IFF) and Professor at the University of Stuttgart and Managing Director of the Fraunhofer Institut für Produktionstechnik und Automatisierung (IPA) in Stuttgart, was born in 1946, graduated in 1977 from the RWTH Aachen on the planning of flexible automated manufacturing systems.

Before rejoining the University in 1988 as the Director of the Institut für Werkzeugmaschinen und Fertigungstechnik (IWF) and Professor at the Technische Universität Braunschweig, he worked for 12 years in the German aircraft (MBB) and electronics industry where he was responsible for the development, planning and introduction of new manufacturing methods and technologies, finally as Director and Head of the Central Department "Production Engineering" of AEG AG Frankfurt.

Chapter 5

Life cycle engineering

Life Cycle Engineering (LCE) refers to a relatively new approach in designing products that incorporates environmental issues and parameters across the entire life cycle of a product. LCE, the discipline of handling the new environmental parameters in product design, now has a strong hold in the manufacturing industry. It is the art of designing the product life cycle through choices about product concept, structure, materials and processes. The life cycle phases include pre-manufacture, manufacture, transportation/distribution, use and disposal of a product. In each phase, the choice of materials, processes, energy consumption, recyclability, etc., are carefully considered from the environmental viewpoint.

A. Y. C. Nee

S. K. Ong

Andrew NEE Yeh Ching, Prof., received his PhD from the Institute of Science and Technology, University of Manchester (UMIST) in 1973. He then joined the University of Singapore in 1974. In 1986 he was appointed as the Director of CAE/CAD/CAM Centre, when it was first established. In 1989 he was promoted to the full professorship. In 1990 he was elected as an Active Member of CIRP and a Fellow of the Society of Manufacturing Engineers. He was the first person in the Asian region to be elected in each case.

From 1993 to 1996 worked as the Head of the Department of Mechanical & Production Engineering and then as the Dean of the Faculty of Engineering. Since 1998 he occupies two directors‘ positions at the university level: Director (Special Projects) of the Office of University Relations, and Director of the Office of Quality Management. Since 1999 he is heading the newly established Office of Admissions and since 2001 he is working as a Deputy Executive Director in the Science and Engineering Research Council (SERC) of the National Science and Technology Board.

A. Y. C. Nee

S. K. Ong

S. K. ONG received her B.Eng. (Honours in Mechanical Engineering) from the National University of Singapore in 1992. She obtained her PhD from the same University in 1996. Currently she is lecturing in the Manufacturing Division in the Department of Mechanical & Production Engineering. She is a member of the Society of Manufacturing Engineers and the Engineering Alumni Singapore.

Now she is the program manager for the Virtual Manufacturing Program in the Laboratory for Concurrent Engineering and Logistics (LCEL) in the Faculty of Engineering. She is also active in the Academic Staff Social Committee, occupying the position of a staff advisor to the Faculty's Students Engineering Club, as well as the chairperson of the Student Self-Development Advisory Committee.

Chapter 6

Fundamentals of parts’ manufacturing

A. M. Dalsci

A. S. Vasiliev

The technology of machine-building manufacture represents a set of various technological processes — casting, forging, punching, heat treatment, painting etc. The technology of machine-building covers the final stages of machine-building manufacture — the work piece transformation into parts and assembly, i.e. the machine manufacturing.

The practice of world engineering is characterized by the requirements to increase the products quality. The speeds, temperatures, accuracy and other parameters are augmented sharply. Involuntarily there is a problem: to what values the separate parameters can be increased, and others - decreased. The answer to this problem is not simple enough.

For additional multimedia material to this topic

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Chapter 6

Fundamentals of parts’ manufacturing

Anton DALSCI, Prof., Dr .Sc. (eng.) graduated from the Bauman Moscow Higher Technical School in 1949. For many years he has been working in the Department for Technology of Mechanical Engineering of the Bauman Moscow State Technical University. He is a merited worker of Science and Technology.

Prof. Dalsci is the author of over 120 publications in the field of Technology of precise Mechanical Engineering.

A. M. Dalsci

Alexandr VASILIEV, Prof., Dr. Sc. graduated from the Moscow Bauman Higher Technical School in 1972. He works in the Department for Manufacturing Engineering of the same Moscow State Technical University, which is now called Bauman.

Prof. Vasiliev is the author of more than 60 publications in the field of precise Mechanical Engineering.

A. S. Vasiliev

High speed machining is an advanced production technology with great future potential. However, as it has been in many other realisations of the technological progress, the implementation of the fundamental knowledge into industrial products, has taken a relatively long time. In this particular case the period of approximately 60 years was not only due to a cautious attitude of the industry, but also to the fact that the existing production facilities corresponding to the state of the art, at the time when the first findings became available from research, did not meet the requirements of high-speed machining.

H. Schulz

Chapter 7

High Speed Machining



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H. Schulz

Herbert SCHULZ, Prof., Dr.-Eng. was born in 1936, studied Mechanical Engineering at the Darmstadt University of Technology and received the title of Dr.-Eng. in Mechanical Engineering. Thereafter he worked as the Technical Sales Manager at Olivetti NC-Machines in Frankfurt, as the Head of Electro Heat Division at WC Heraeus in Hanau and then as the Executive Vice President at Scharmann GmbH & Co. in Mönchengladbach.

In 1981 he became the Director of the Institute of Production Engineering and Machine Tools (PTW) of the Darmstadt University of Technology and in 1987 - the Dean of the Faculty of Mechanical Engineering of the Darmstadt University of Technology. He has a great amount of experience in high speed cutting technology, design of hsc-machine tools and components, development of special tools for high speed manufacturing and also in specific CAD/CAM systems. The scientific output of this research are 36 dissertations, 257 publications, appr. 260 papers and 4 books.

Chapter 8

Aspects of manufacturing systems’ integration

A. I. Dashchenko W. Pollmann O. A. Dashchenko

This chapter presents research conducted within the field of modular manufacturing machine synthesis. The focus within this field lays in optimising technological processes of the initial stage. It is easier and less expensive to optimise a process in the initial stage than to alter finished equipment. The concept employs computer-aided search in the initial stages of process planning. This concept has already proved valid for mass and serial manufacturing. Therefore, it is being further developed to suit flexible manufacturing systems; the main goal thereby is to create cost-effective solutions for various types of manufacturing.





Chapter 8

Aspects of manufacturing systems’ integration

A. I. Dashchenko

Anatoly I. DASHCHENKO, Scientific Editor of this book, Merited Worker in Science and Engineering of Russia, Prof., Dr.-Eng., Dr. Sc., Head of the Department "Complex Automation in Machinebuilding” TU <<MAMI>>, Academician of International and Russian Academies of Electrotechnical Sciences, Member of Society of Automotive Engineers Inc. (N.Y.). was born in 1929.

The range of his scientific interests includes:

• Theory and practice of complex automation of industry, based on new technologies,• Problems of analysis and optimal synthesis of technological machines and machine systems (incl. reconfigurable) designed on the module principle,• New methods of calculation and experimental research of productivity, accuracy of work of such systems, including methods of statistical modelling.

He is the author of 19 books, more than 185 articles (60 of which are published in different international editions) and has 7 patents and inventions.

Werner POLLMANN, Prof., Head of Editorial Board of this project was born in 1941 in Paderborn. After studying mechanical engineering at the University of Hannover he worked as an assistant to the Chair of Design at the University of Stuttgart. In 1969 he joined DaimlerChrysler.

After several years in the field of Manufacturing and Engineering, Prof. Pollmann became Senior Vice President for Production and Material Research and Chief Environmental Officer in 1990. In 1995 he was appointed Professor of Construction and Manufacturing at the University of Stuttgart.

W. Pollmann

O. A. Dashchenko

Oleg A. DASHCHENKO, Manager of this book-project, Dr.-Eng., researcher at the DaimlerChrysler AG, was born in 1962 and graduated from the Moscow State Technical University <<MAMI>> in 1985. After several years of practical work as the development engineer he finished his PhD in the field of assembly automation. Since 1993 has been working as a researcher at DaimlerChrysler.

The range of his scientific interests includes:

• Theory and practice of assembly automation in automotive industry; • New assembly, machining and internal combustion engine technologies.

He is the author of 6 patents (4 of them joint international patents) and of about 12 articles in different European editions.

Chapter 9

CAPP systems for machining, assembly and disassembly

M. Santochi

This chapter discusses some issues regarding the application of CAPP (Computer-aided Process Planing) systems in the fields of machining, assembly and disassembly. A few examples of successfully tested CAPP systems, are presented and discussed. Some conclusions on the future predictable developments of CAPP systems are finally drawn.



M. Santochi

Marco SANTOCHI, full Professor of manufacturing engineering at the Faculty of Engineering of the University of Pisa since 1990. He occupies the position of the Head of the Department of Production Engineering at the University of Pisa and now he is the Head of the Production section of the Department of Mechanical, Nuclear and Production Engineering.

His research activity carried out in various areas like sensors for cutting process monitoring, adaptive controls for machine tools, CAPP, automated assembly, recycling of used consumer products.

Prof. Santochi is an active member of CIRP with the role of the Technical Secretary and Chairman of the STC Assembly, Member of SME (Society of Manufacturing Engineers), responsible of a national research project on CAPP, responsible of the monitoring of the National Research Project on Industrial Design, Expert Assessor at the EC for research projects.

Chapter 10

Results of machine-tool and assembly systems’ modelling

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Statistical simulation is used to analyse complex manufacturing systems (MS). The method is based on the statistical laws of technical systems. Statistical simulation can be applied in varied situations. For example, one could apply statistical simulation when analysing machine-tools or assembly lines.

The question is, should one analyse machine-tool/assembly lines using statistical simulation? When working positions/machine tools in an area are connected by rigid transports, the main parameters of such blocked-together "simple" systems can be evaluated using elementary formulae. A model of a blocked-together system is examined in this work at a later time.

A. I. Dashchenko W. Pollmann O. A. Dashchenko





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Chapter 11

Cybernetic structures, operationsand control of work systems in manufacturing

J. Peklenik

This contribution presents some thoughts about the importance of the Cybernetics, the new scientific discipline, developed by N. Wiener, on the manufacturing science and technology. The foundation of the approach is the Elementary Work System (EWS). It is analysed from the cybernetic and information viewpoint. The subject’s competence, as a decisive factor for structuring, operating and controlling the EWS is discussed in detail. The influence of the human factors on the competence is explained. The control of EWS should consider the information as well as the cybernetic laws. The conventional factory system and an EWS adaptive network are briefly discussed

J. Peklenik

Janez PEKLENIK, Prof., Dr.Eng., habil. was born in 1926 and is now working as the Head of Department of Control and Manufacturing Systems at the University of Ljubljana. He is also the President of the Engineering Academy of Slovenia and Fellow of the International Institution for Production Engineering Research (CIRP). In 1979/80 he was the President of CIRP. His research interests are:

• Online identification of manufacturing processes (cutting, grinding),• Adaptive control,• Automation of manufacturing systems,• Surface charactirisation,• CA/group technology,• Generative CAPP,• Complex systems in manufacturing.

Prof. Peklenik is the author of more then 220 publications and 11 patents.

Chapter 12

Rapid Prototyping (RP) in Manufacturing

Rapid Prototyping is the name for a group of novel part manufacturing processes relying on the quick solidification of a loose material. They are supposed to be faster and more flexible than conventional techniques and therefore suited particularly for producing prototypes in a very short time.

F. H. Rehsteiner





Chapter 13

Challenges in electronic production Increasing demands referring to the quality and the

functionality of electronic systems have contributed to a growing diversity of component packages. Therefore the Surface Mount Devices (SMD) have, except components for high power and high mechanical strain (plugs, sockets, etc.), replaced devices in Through Hole Technology (THT).

K. Feldmann

K. Feldmann

Klaus FELDMANN, Prof., Dr.-Eng. was born in 1943, studied production engineering at the Technical University of Berlin. He earned his doctorate at the Institute of Professor Spur on his scientific research on design optimisation of automated lathes.

After some years of working as the R&D Manager in the fields of automation and assembly technology in Erlangen and as the production manager at the plant in Amberg he has become the Head of the Institute for Manufacturing Automation and Production Systems (FAPS) at the University of Erlangen in 1982. He is the Speaker of some collaborative research areas, and the Chairman of the Research Association ”Molded Interconnect Devices – 3D-MID”. More over he is an active member of national and international science communities.

Chapter 14

Electronic-vacuum technologies

L. I. Volchkevich

Y. I. Panfilov

Electronic-vacuum Technologies (ET) are material’s treatment process based on physical phenomenon of high energy flow particles (electron, ion, atom and molecule beams and optic, infrared and X-rays radiation as well) and can operate on any material. There are other names of ET such as “Electron-Ion-Plasma Technologies”, “Elion Technologies” as well. A number of ET processes are untraditional for machine building – vacuum technological fluid creation is the most important of them.

L. I. Volchkevich

Leonid I. VOLCHKEVICH, Prof., Dr. Sc. (techn.) was born in 1930 and is now the Head of Department of Electronic Technology in machinery at the Moscow Bauman State Technical University.

His main scientific interests are:

• Productivity and reliability theory,• Design and Investigation of automated production lines, • Economy of manufacturing and technical politic.

Prof. Volchkevich is the author of more than 300 scientific publications.

Y. I. Panfilov

Yuriy V. PANFILOV, Prof., Dr. Sc. (techn.) was born in 1948 and is working in the Department of electronic technology in machinery at the Moscow Bauman State Technical University.


• Thin film deposition in vacuum,• Ultra pure technological environment,• Electron-ion-plasma treatment methods in electronic industry.

Prof. Panfilov is the author of more then 150 scientific publications.

Chapter 15

New solid state lasers and their application potentials

In recent years, NdYAG-lasers have been found to show increasing interest in many fields of high-power applications that formerly had been the domain of CO2-lasers. This was

mainly due to several consequences of their wave length, such as a higher absorptivity, lower sensitivity against laser-induced plasmas and, in particular, the use of flexible glass fibers for beam handling.

H. Huegel

H. Huegel

Helmut HUEGEL, Prof., Dr.-Eng. performed his research work in the field of gas-dynamic lasers and electrically excited gas flow lasers with emphasis on capacitive rf-excitation. In 1986 he was appointed as the full professor and Director of a new institute to be built at the University of Stuttgart.

His main interests are:

• Development of lasers (high-power rf-excited CO2, diode- pumped solid state; new concepts of high-power diode lasers),• Optical systems for beam guiding and shaping and laser processing.

From 1990 to 1992 he was the Dean of the Faculty of Construction, Design and Production Engineering and from 1995 to 1996 the President of Scientific Society for Laser Technology. Since 2000 he has become the Chair of the Scientific Board of Max-Born-Institute in Berlin.

Prof. Huegel wrote numerous publications in the fields of plasma-technology, gas lasers, material treatment processes and is an author of "Strahlwerkzeug Laser" (Teubner 1992), the first German textbook on laser technology for engineering students.

Chapter 16

New information technologiesin industrial activity of the enterprises (IAE)

The rapid technological development of powerful information and communication technologies (ICT) has a major impact on enterprises and on their business processes. Along with globalisation and internationalisation, information and communication technologies are changing the working culture, the enterprise organisation and the workflow.

R. Anderl

Reiner ANDERL, Prof., Dr.-Eng. was born in 1955 and studied mechanical engineering at the University of Karlsruhe, where he received his diploma in 1979 and then his doctorate degree in 1984. From 1984 to 1985 he took the position as the Technical Manager of a medium sized company. Since 1985 he has been working as the Chief Engineer at the Institute for Applied Computer Science in Mechanical Engineering (RPK) at the University of Karlsruhe. In 1991 he habilitated and in 1992 has got the venia legendi, which includes the authorization to teach CAD/CAM technology. In April 1993 he received the professorship for computer integrated design in the Faculty Mechanical Engineering at the Darmstadt Technical University.

Prof. Anderl´s main research activities are advanced CAD-technologies, CAX-integration, product data management (PDM), product data technology and design methodologies.

R. Anderl

Chapter 17

Modelling of technological and production processes

V. V. Gornev V. F. Emelyanov S. I. Iassinovski

Intellectual manufacturing is based on the organisation of work with knowledge and therefore, the new structure of manufacturing organisation and new principles of manufacturing management. Intellectual manufacturing (IM) and intellectual machine building enterprises (IME) have just begun developing and while creating any complex system it is necessary to develop the scientific basis of intellectual manufacturing, its models and to study its behaviour.

V. V. Gornev

Vadim F. GORNEV, Prof., Dr. Sc. (eng.), Academician of the International Academies of Information and Sciences of higher school was born in 1931. He has a rank of the European Teacher of Engineering of HIGHER SCHOOL (under the register IGIP) and is working now as the Head of the Department for Computer Automated Systems and Computer Systems of Automated Production.

His sphere of activity encompasses:

• Complex automation of manufactures on the basis of new:• Information technologies,• Intellectual enterprises. New computer-oriented training technologies.

Prof. Gornev is the author of more then 150 publications in the field of automation in mechanical engineering.

V. F. Emelyanov

Victor V. EMELYANOV, Prof., Dr. Sc., B. Sc., M. Sc. was born in 1949 and is now working at the Moscow Bauman Higher Technical School as the Head of the Department of Computer-Aided Systems for Manufacturing Automation. He began his research work in 1973.

His main scientific activities were carried out in the fields of research and development of the method for specifying optimal strategy of on-line management in manufacturing and theoretic basis, and method of building intelligence models for making decision in CIM management and simulation. Hi is also involved in research on artificial intelligence methods and systems, CIM, complex discrete systems simulation, analysis and design, production management, multi-agents systems.

Prof. Emelyanov is the author of the 5 books and more than 150 scientific papers in the field automation, production management, simulation. He is a member of the Editorial Boards of the journals ”Software&Systems” and ”AI News”.

C.V.

S. I. Iassinovski

Chapter 18

New machine tools and systems

18.1. New Machine Tools for New Manufacturing Processes. M. Mandelli18.2. Intelligent machine tools. T. Nagao, Y. Hatamura, M. Mitsuishi, M. Nakao18.3. Modern Concepts for Machine Tools. F. Rehsteiner

18.2.1. Necessity of Global Intelligent Manufacturing in Modern Societies T. Nagao, Y. Hatamura, M. Mitsuishi, M. Nakao

18.2.2. Development of an Intelligent Machining Center T. Nagao, Y. Hatamura, M. Mitsuishi

18.2.3. Development of an Intelligent Face Grinding Machine Y. Hatamura, M. Nakao


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Chapter 18

18.2 Intelligent machine tools

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M. Mandelli

The machine tool industry is enjoying a period of fast innovation, driven by end-users that have re-discovered the importance of production, after a long period, during which finance and marketing seemed to be the sole instruments to reach industrial success. Innovation is also pushed by internal pressure: European manufacturers must keep proposing new solutions to face the evolution of a market that is more and more competitive.

In the case of machine tools, the market is particularly pressing. Machine tools are used to produce other machines, they are one basic factor of competitiveness for mechanical firms.

Chapter 18

18.1 New machine tools for new manufacturing processes

Massimiliano MANDELLI, Dipl.-Eng., after his degree in mechanical engineering from Politecnico of Milan, he began his working experience at two of the main Italian machine tool manufacturing companies. In 1989 he joined UCIMU, the Italian Association of machine tool manufacturers, which today covers the position of technical manager.

He is active in supporting member companies for innovation and product development. He co-operates with Politecnico of Milan and University of Brescia for lectures related to machine tools and mechanical technology. Associate member of CIRP, he is the author of more than 30 technical publications.

Mr. Mandelli is involved in many national and international commissions dealing with technical developments in the machine tool sector.

M. Mandelli

T. Nagao Y. Hatamura M. Mitsuishi M. Nakao

Strong demands are in place on modern manufacturing systems, especially on those machining systems for cutting and grinding. These demands include high efficiency, high accuracy, conformance to information systems, and low impact on the environment. The authors have introduced intelligence into manufacturing systems to satisfy two of these needs, namely higher accuracy and support of information systems.

18.2.1. Necessity of global intelligent manufacturing in modern societies

T. Nagao

Takaaki NAGAO, Prof., Bachelor, Master & Doctor of Eng. in mechanical engineering at the University of Tokyo is now working at the Kochi University of Technology in the Department of Intelligent Mechanical Systems Engineering. He graduated from the University of Tokyo in 1961.

Main fields of research are production engineering, materials processing, mechanics of granular materials, production economics.

Y. Hatamura

Yotaro HATAMURA, Prof., PhD studied mechanical engineering at the University of Tokyo and later made his PhD at the same University. During many years Prof. Hatamura worked in the field of design theory and methodology, metal casting and design, mechanics of powder, intelligent processes, construction machinery, machine tolls, force sensors/actuators, information processing machines, micro-machining, bio-mechanics, technology transfer and education.


• Fabrication of 3D micro structure, • Nano-manufacturing world,• Multi-axial force sensing, • Intelligent manufacturing, • Preventing crashes of magnetic disk heads,• Principles of creative design,• Metal forming with vibration.

Prof. Hatamura is a member of CIRP (International Institution for Production Research), ASPE (American Society of Precision Engineers), JSME (Japan Society of Mechanical Engineers), JSPE (Japan Society of Precision), the Robotics Society of Japan, Society of Powder Technology Japan, Japan Electronics Society of Packaging, Japan Medical Society of Voice and Speech, the horological Institute of Japan.

M. Mitsuishi

Mamoru MITSUISHI, Prof. is working at the Department of Engineering Synthesis, Faculty of Engineering at the University of Tokyo. In 1984 he got his Masters of Engineering in mechanical engineering at the University of Tokyo. Two years later he obtained a title of Doctor of Engineering in Mechanical Engineering at the same University.

Prof. Mitsuishi worked as a lecturer at the University of Tokyo as a visiting professor at the Fraunhofer Institute for Production Technique and Automation (IPA) in Stuttgart and as the Associate Professor at the University of Tokyo. Now he is working as a professor at the University of Tokyo.

M. Nakao

Masayuki NAKAO, Ass. Prof., Dr.-Eng. was born in Tokyo, in 1958. He received the B.E., M.E. and Dr.-Eng. degrees from the University of Tokyo in 1980, 1982 and 1991 respectively.

Since 1982 he had been engaged in the development of thin film disk in Hitachi Metals, Ltd. and HMT Technology Corporation.

Since 1992 he has been involved in the research of micro manufacturing as an associate professor in the Department of Engineering Synthesis at the University of Tokyo.

18.2.2 Development of intelligent machining center

M. Mitsuishi Y. Hatamura T. Nagao

The authors have developed a high efficiency machining system which maintains a stable cutting state using multi-axis force information from sensors installed on the table of a machining center. The implemented system has the capability for cutting state monitoring, adaptive control by modifying the spindle speed and the feed speed in real-time, and learning through the storage of an “experimentally determined stability lobe diagram'' which incorporates knowledge representing the relation between machining conditions and the machining state.

18.2.3 Development of an intelligent face grinding machine

M. Nakao

Y. Hatamura

Information processing devices handle thin substrates, such as silicon wafers, glass lithography masks, ceramic circuit boards and glass display boards. These substrates are 8-inch or larger in diameter with ultra-flatness of some 0.1 m per 200 x 200mm.

Current processes for finishing the substrates are lapping and polishing. These processes suffer from low material removal rate, and large machine footprints, e.g., a 5m lapping plate used in a 2-hour batch processes to average out variation in the removal with an alternative in individual grinding. Various factors interfere with conventional grinding of such substrates; the grinding force causes deformation at the rotary bearing; irregular thermal expansion bends the column; the table tilts along the linear guide etc.

Chapter 18

18.2.3 Modern concepts for machine tools In this chapter an arbitrary selection of three novel

developments in the design of machine tools is presented. All of them concern the machine tool properly speaking, i.e., neither software and communication aspects nor networked systems like flexible manufacturing systems are addressed. These latter fields, demanding as they may be, at least in their function of presenting a ”background support” to the actual production work have reached a high level of maturity and therefore need not be discussed here.

All of the three selected topics: Non Cartesian machine tool kinematics; doing away with idle time between different processes, and improving the dynamics of large machine tools, can not be considered as ”mature” by any means at the time of this writing. This holds true for their technology as well as their acceptance by the users. The intention here is to give the reader an idea of ”where could the voyage go”, and to show him that quantum leaps forward are still possible.

F. H. Rehsteiner

Y.Koren U. Heisel F. Jovane T. Moriwaki

G. Pritschow G. Ulsoy

Strong demands are in place on modern manufacturing systems, especially on those machining systems for cutting and grinding. These demands include high efficiency, high accuracy, conformance to information systems, and low impact on the environment. In this chapter an arbitrary selection of some novel developments in the design of machine tools is presented. All of them concern the machine tool properly speaking, i.e., neither software and communication aspects nor networked systems.

H. Van Brussel


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Chapter 19

Reconfigurable manufacturing systems

Chapter 19




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Y.Koren

Yoram KOREN, PhD., B.Sc., M.Sc is the Paul G. Goebel Professor in the College of Engineering at the University of Michigan. Since 1996 he is the founding Director of the National Science Foundation (NSF) Engineering Research Center (ERC) for Reconfigurable Machining Systems.

Prof. Koren is recognized as the founder and worldwide intellectual leader of a new scientific discipline, reconfigurable manufacturing systems (RMS) and has published 220 refereed papers and 3 books in the automated manufacturing field. His books have been translated into Japanese, French and Chinese, have won two prestigious awards, and are used as textbooks at universities around the world. He holds seven U.S. patents in flexible automation and three additional are pending.

Prof. Koren is a Fellow of both the Society of Manufacturing Engineers – SME and .the American Society of Mechanical Engineers – ASME. He received several awards including the SME 1984 Textbook Award (given for Koren’s book Computer Control of Manufacturing Systems; published by McGraw Hill), and the 1999 William T. Ennor Manufacturing Technology Award given by the Society of Mechanical Engineers – ASME International.

U. Heisel

Uwe HEISEL, Prof., Dr.-Eng., Dr. h. c. mult. was born in 1945. He studied mechanical engineering in Berlin and received his doctor's degree in 1979 with a thesis about "Possibilities to Compensate Thermal Displacements".

In 1980 he joined a machine tool company as a development engineer and took over the management of the department for design of manufacturing systems after a short time. In 1982 he was appointed Head of the Mechanical Development and Design. In 1988 Prof. Heisel was called to the Institute for Machine Tools (IfW) at the University of Stuttgart as Professor and Managing Director. Within his research work he is concerned with machine tool design, machining processes, automatisation and woodworking technologies.

Current research projects include the development of new design for machine tools, especially with parallel kinematic structures.

F. Jovane

Francesco JOVANE, full professor of "Tecnologie Meccaniche" (Manufacturing Technologies) at the University of Bari and full Professor of "Sistemi Integrati di Produzione" (Integrated Production Systems) at the Politecnico di Milano.

He carried out scientific activities at the Institute of Technology, Naples University; National Engineering Laboratory, East Kilbride (GB); Massachusetts Institute of Technology, MIT, Boston (USA); University of California, Berkeley (USA); Institute of Technology, Bari University; Department of Mechanical Engineering, Politecnico di Milano.

Prof. Jovane is the author of 140 papers in the field of manufacturing and innovation. He is working as the Director of ITIA - Institute of Industrial Technologies and Automation, National Research Council of Italy (CNR) and is a member of the Commettee for conceiving the National Research Program on Innovating Production System, launched by the Ministry of University and Scientific and Technological Research.

T. Moriwaki

Toshimichi MORIWAKI, Prof. of mechanical engineering at the Kobe University in Japan was born in 1944 and is working as a Dean of the Engineering Department.

His Research Interests include:

• Intelligent manufacturing systems and machine tools,• Ultraprecision machining and machine tools, • Dynamics and thermal behavior of machine tools, • Sensor technology in manufacturing, ergonomics in manufacturing.

He is a member of the Japan Society of Mechanical Engineers (JSME), of the Japan Society of Precision Engineering (JSPE), of the American Society of Mechanical Engineers (ASME), International Institution for Production Engineering Research (CIRP, Active Member), American Society for Precision Engineering (ASPE), European Society for Precision Engineering and Nanotechnology (EUSPEN) and was awarded with the F.W. Taylor - Medaille in 1976.

G. Pritschow

Guenter PRITSCHOW, Prof., Dr.-Eng., Dr. h.c.mult. was born in 1939. He studied telecommunication technology at the Technical University of Berlin from 1959 to 1966. Afterwards he worked for 12 years in research management positions in industry. From 1976 to 1980 he taught automation technology for quality assurance and manufacturing at the Technical University of Berlin.

Since 1984 he is the Director of the Institute for Control Engineering of Machine Tools and Manufacturing Units at the University of Stuttgart. Important research work is done by the Institute concerning direct drives, open controllers, parallel kinematic machines and control algorithm for positioning controllers.

G. Ulsoy

Galip ULSOY born in 1950 is the William Clay Ford Professor of Manufacturing and Chair of the Department of Mechanical Engineering at the University of Michigan (UM). He has been at the UM since 1980 and has served as the Director of the Program in Manufacturing, Associate Chair of the Department of Mechanical Engineering and Applied Mechanics as well as the Chair of the Mechanical Engineering Graduate Program.

Prof. Ulsoy is interested in dynamic modelling, analysis, and control of mechanical systems; particularly manufacturing systems. His research work utilises a combination of experimental, analytical, and numerical methods. He has made basic research contributions to the mechanics of axially moving elastic systems (e.g., translating bands, rotating shafts), and to control system design (e.g., state derivative feedback, coupling between modelling and controller design).

H. Van Brussel

C.V.

R. D. Schraft

The demand for high-quality automation solutions remains constant. Existing deficits and rapid advances in innovations, especially in the fields of information and sensor technology, aim to improve the abilities of robots with regard to their ability to adapt to changing manufacturing conditions, their ability to be quickly configured to carry out production tasks and their intuitive operation in all operating modes from installation and operating tasks right up to maintenance.


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Chapter 20

Robot technology

Chapter 20

Robot technology



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Robot technology

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Robot technology

Rolf D. SCHRAFT, Prof., Dr.-Ing., Dr. h.c. mult. was born in 1942. Presently he is the Director of the Fraunhofer Institute for Manufacturing Engineering and Automation (IPA), Stuttgart. Prof. Schraft studied Mechanical Engineering at the University of Stuttgart and graduated in 1969. He got his Dr. degree in 1976.

He started the research group for Material Handling and Assembly at the IPA, which did numerous projects and developments for national and international research agencies and mainly for industry. Currently he is very much involved in promoting and developing service robots.

Since 1977 he has been a lecturer at the University of Stuttgart and since 1981 also at the University of Dortmund. Since 1986 he is honorary Professor at the University of Dortmund.

Prof. Schraft received in 1986 the Golden Robot Award, in 1990 the JIRA Award (Japanese Industrial Robot Association), Japan and in 1992 the Joseph Engelberger Award, from the Robotics Industries Association, USA. In 1997 the University of Timisoara/Romania conferred the ”Doctor honoris causa” to Prof. Schraft. In 1998 the Georgian Technical University of Tiflis/Georgia conferred the ”Doctor honoris causa” to Prof. Schraft. Since May 2000 he is speaker for the head of the Fraunhofer IPA

He published more than 440 publications in national and international journals and 40 books and contributions for books.

R. D. Schraft

Chapter 21

Methods for control, testing, diagnostics and reliability calculation of automatic equipment

and technological system of machines

N. N. Kluev E. G. Nachapetjan V. V. Sherbakov

Quality is important at all levels since it involves technological processes, service and environment. Great efforts are being put into investigating the relations between quality, innovation and research.

More than hundreds of physical methods and thousands of different types of units are used today in non-destructive testing (NDT) and diagnostics for solving the new approaches to technological problems of quality.

V. N. Kluev

Vladimir KLUEV, Prof., Dr. Sc. (techn.), Corr.-member of the Russian Academy of Science, Member of the European Academy, the leading scientist in the field of electromagnetic, radiographic and acoustic non-destructive methods for metals and articles quality assurance. Since 1970 he works as the Director General of the Research Institute of Introscopy of Moscow-Scientific-Industrial Association "Spectrum", awarded by several State Prizes.

He is the author of approximately 100 patents, 268 research papers including 18 monographs and made a big contribution to the development of instruments for vibration measurements, radiographic computerized tomography, the theory of electromagnetic control of moving items and electromagnetic modulating defectoscopy.

E. G. Nachapetjan

Evgeny NACHAPETJAN, Prof., Dr. Sc. (techn.) was born in 1922 and works now as an employee of the Mechanical Engineering Research Institute of the Russian Academy of Science (IMASH RAS) named after A. Blagonravov. He is a leading specialist in the field of NDT and diagnostics of mechanisms.

He is the author of 5 monographs and 120 research papers and participated in the development of technological equipment mechanisms diagnostics for evaluation of their technical level and condition.

V. V. Sherbakov

Victor SHERBAKOV, Dr. Sc., senior scientist, works as a leading specialist at the Mechanical Engineering Research Institute of the Russian Academy of Sciences. He is also a skilled specialist in the area of experimental dynamics and diagnostics of automated mechanisms.

He has conducted a big volume of theoretical and experimental research on the definition of quality criteria of the mechanisms of automated equipment diagnostics and of mechanical processes at different stages of machine life cycle. He has also conducted a number of developments of the methods of qualimetric estimation of quality and certification of the mechanisms of technological equipment, industrial robots and automated methods and means of control and diagnostics of automatic equipment.

A number of his developments have found practical realisation in Industry. Dr. Sherbakov has published more than 50 scientific articles.

Chapter 22

Prospects of the technologies development

The 21st century has had a great impact on the information revolution in changing our society towards the new creation of the information society with much emphasis on individual pleasure through convergence of time, distance and place. Its nature of uncertainty due to the inexperienced new individual based communication and network maybe received confusion and chaos on the traditional mind, however, it will be transformed as an excellent opportunity to the challenge and dynamism for new upcoming generation. Factory automation and robots will perform to converge our traditional industrial society with the new information society and vice versa. In addition factory automation and robots with networked intelligence will generate the great unlimited opportunity as a bridge to bundle cultural behavior in manufacturing. A new vision for the future will be provided with our insights on factory automation with information technology.

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of FANUC Ltd lead by Mr. Inaba


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FANUC`s businesses were founded in 1956 when it started to develop numerical control (NCs) and servo systems. FANUC LTD was established in July 1972 when the Computing Control Division became independent from FUJITSU.

Since its founding, FANUC has always emphasized research and development in its management.

”Technology has a history. But engineers have no past. They only need to create.” These words of Dr. Inaba, the founder of FANUC spell out FANUC`s stance on technological development.

Injection Molding Machine FactoryThe factory has a capacity to produce 200 ROBOSHOTs a month. The machining area is equipped with the latest "FANUC CELL 60" which enables un-manned operation even on holidays. All production processes from machining to assembly are performed at FANUC to deliver high quality products.

Tsukuba FactoryThe factory at the foot of Mt. Tsukuba has a capacity to produce 400 ROBOCUTs and ROBODRILLs a month. It is fully networked by the LAN system, which enables all relevant information from design, sales to production to be comprehensively controlled - resulting in a highly advanced CIM system.

Servo Motor FactoryThe factory is equipped with the most advanced robotic automation system. All work processes from receiving motor parts, assembling, testing, packing to shipping are automated by using robots.It has a capacity to produce 50,000 motors of approximately 2,000 different kinds a month.The motor parts are stored in the state-of-the-art automatic warehouse, which is linked to distributed warehouses on the production floor, from which the robots take out the parts and perform automatic assembly.

Hayato FactoryThe factory in Kagoshima Prefecture is dedicated to the production of servo motor sensors and has a capacity to produce 50.000 units a month. The machining and assembly lines are fully robotized to perform highly efficient production from parts machining, assembling to testing.

Sheet Metal FactoryThe Sheet Metal Factory is manufacturing the cabinets for FANUC robot controllers. This is the state-of-the-art factory, where every process from cutting to assembling is fully robotized.

Chapter 23

Perspectives of innovative technologies in manufacturing

The majority of mechanical engineering products today are characterised by a close interaction between classical mechanics with electronics, control engineering and software, expressed aptly by the term mechatronics. However, further possibilities are emerging that extend way beyond the scope of mechatronics - systems with inherent intelligence. Future systems in the area of mechanical engineering will comprise configurations of intelligent system elements, which we also refer to as solution elements since they enable the solution to a function. The performance of the overall system is characterised by the communication and co-operation between intelligent system elements. In terms of software, this involves distributed systems of interacting agents.

J. Gausemeier



Chapter 23

Perspectives of innovative technologies in manufacturing

J. Gausemeier

Juergen GAUSEMEIER, Prof., Dr.-Eng., is professor of computer integrated manufacturing at the Heinz Nixdorf Institute, University of Paderborn since 1990. He graduated in 1977 from the Institute for Machine Tools and Production Engineering at the Technical University Berlin. His doctoral thesis supervisor was Professor Spur. During his industrial career, Prof. Gausemeier was Head of Engineering for CAD/CAM systems for ten years. His last position was Division Manager for Process Control System at a well-known Swiss company. Additional to his professorship he is a Member of the Board and the Managing Director of the scientific society ”Berliner Kreis – Wissenschaftliches Forum fuer Produktentwicklung e.V.”.

Prof. Gausemeier has written more than 180 publications for scientific journals and also for national and international conferences. There are three books to emphasise (published by Carl Hanser Verlag).

Multimedia Attachment to the Book Manufacturing Technologies for Machines of the Future Multimedia Attachment to the Book Manufacturing Technologies.

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