PRECIS
Book Review
Precision Machine Design
Alexander H. Slocum
Prentice Hall, 1992, 750 pp., $62.00
Alexander Slocum's Precision Ma-
chine Design provides an insight into
the engineering design process for a
precision machine. Slocum, a faculty
member in the Department of Me-
chanical Engineering of the Massa-
chusetts Institute of Technology and
the author of numerous articles on
precision fixtures and mechanisms,
has written this book to serve as both
an advanced engineering design
textbook and a reference for the prac-
ticing engineer. The text begins by
outlining the steps of the generic de-
sign process (e.g., economic analy-
sis, project management, brain-
storming, conceptual design), then
goes on to discuss issues germane to
the design of a precision machine,
such as error budgets, metrology
frames, and error mapping. Through-
out his book, Slocum underscores the
fact that a precision machine de-
mands "painstaking attention to de-
tail" in every aspect of the design
process.
Slocum's 700 + page work is not
for the faint of heart. Not too far into
the preface, the reader will undoubt-
edly sense the author's enthusiasm
for the subject and will realize the im-
pending challenge of keeping pace
with the author. However, although
this book covers a wide range of top-
ics, most of the subjects are thor-
oughly discussed and, for those top-
ics that are less detailed, numerous
references are cited for further study.
In addition, several case studies have
been incorporated into the text to il-
lustrate how precision engineering
issues can be successfully addressed.
In Chapter 1, Slocum introduces
the elements of the design process.
This introduction begins with brief
discussions of economic analysis
(e.g., the time value of money, cash-
flow analysis, rate of return calcula-
tion) and project management con-
cepts and techniques (e.g., the CPM
method, cost and time estimation).
Next, Slocum lists the attributes of a
PRECISION ENGINEERING
good design engineer, emphasizing
the importance of thinking creatively,
keeping informed, and observing the
world around us. Next, methods are
suggested for developing several
conceptual designs and then system-
atically selecting the best design. The
many considerations (e.g., kinemat-
ics, dynamics, ergonomics, mainte-
nance) in the design of machine tools
are presented in an outline that
should prove useful to any engineer.
The chapter concludes with very en-
lightening case studies of the design
processes for a high-speed machin-
ing center and a coordinate-measur-
ing machine.
Chapter 2 discusses the perfor-
mance issues of accuracy, repeatabil-
ity, and resolution. The error budget
is introduced as an excellent tool for
the preconstruction estimation of
machine and environmental errors.
The homogeneous transformation
matrix is presented as a method for
modeling the effects of various ma-
chine errors. Typical error sources
are identified (e.g., temperature vari-
ations, gravity, variable process
loads), and various techniques are
suggested for minimizing errors.
Chapter 2 ends with a case study of
leadscrew-induced carriage straight-
ness-of-motion errors.
Slocum devotes three chapters
to the discussion of sensor issues.
Chapter 3 defines various terms used
in the discussion of sensors (e.g., ac-
curacy, frequency response, hystere-
sis). Chapter 3 also discusses the
operation, typical performance char-
acteristics, and applications of non-
optical sensors such as capacitance
probes, hall effect sensors, inductive
sensors, LVDTs, and so forth. Chapter
4 is a discussion of operating princi-
ples, performance characteristics,
and applications for various optical
sensors, including autocollimators,
optical encoders, and interferometric
sensors. Chapter 5 presents sensor-
related issues, such as sensor loca-
tion, alignment, mounting, and envi-
ronment. The concept of the metrol-
ogy frame is introduced as a means
of achieving a reference that is unaf-
fected by the machine process. Sen-
sor calibration issues (e.g., repeat-
ability, systematic uncertainty, samp-
ling rate) are discussed. Finally, a
case study of the design of a laser
telemetric system is presented.
Chapter 6 is a detailed case study
of machine error compensation. This
case study discusses the construction
of a homogeneous transformation
matrix for a turning center, the map-
ping of the machine's geometric and
thermal errors, and the development
and implementation of a real-time er-
ror compensation scheme.
Various design considerations
are discussed in Chapter 7. These is-
sues range from manufacturability
and material selection to structural
design and support system require-
ments. The chapter begins with a dis-
cussion of the available fabrication,
heat treating, and plating techniques.
Next is an examination of material
selection issues (e.g., strength, ther-
mal expansion, thermal conductiv-
ity). The sections on structural and
joint design focus on issues such as
minimizing vibration transmission
and distortion and maximizing damp-
ing and thermal stability. Bolted
joints, pinned joints, adhesive joints,
etc., are examined in terms of stiff-
ness, stability, permanence, and so
forth. The section on support systems
emphasizes the importance of sys-
tems and components such as safety
systems, coolant system equipment,
sealing systems, and tooling and fix-
turing hardware.
Chapters 8 and 9 discuss contact-
ing and noncontacting bearings, re-
spectively. Slocum provides explana-
tions of the various bearing designs,
methods for analyzing existing bear-
ing designs, and designing custom
bearings. The information on the
commercially available bearings in-
cludes system performance data
(e.g., range of motion, accuracy, re-
peatability, load capability) and typi-
cal applications.
In the final chapter, the issues
related to power generation and
transmission are discussed. The dis-
cussion begins with a procedure for
51

the dynamic matching of these com-
ponents to the specific machine re-
quirements such as stiffness, force,
or torque capacity. The chapter also
includes an examination of var-
ious types of motors and actuators
(e.g., voice coils, piezoelectrics, hy-
draulics), noninfluencing coupling
mechanisms, and transmission com-
ponents (e.g., belts, gears, traction
drives, leadscrews). The book ends
with a case study involving the use of
real-time control to increase the axial
stiffness of an instrument-position-
ing stage.
Although a single text cannot
fully address every issue encoun-
52
tered in the expansive realm of preci-
sion engineering, Precision Machine
Design does consolidate a wealth
of material into one volume. This
book summarizes fundamental de-
sign principles, outlines analysis
techniques, presents representative
data for a range of machine compo-
nents, and discusses how these com-
ponent characteristics influence the
performance of a precision machine.
The author's casual writing style may
appeal to some readers, but others
may be distracted by the numerous
tangential references and editorials.
For the most part, the graphics are
adequate (in several illustrations the
PRECIS
components are not well labeled), but
a few more illustrations would have
been helpful.
This book could serve as a course
text, although no homework prob-
lems are provided. This book should
also prove to be a valuable reference
despite the rather abbreviated index,
which could make locating a specific
subject difficult. However, because of
the breadth of coverage, I would rec-
ommend the book to anyone inter-
ested in precision engineering design.
Donnie Moorefield
J A N U A R Y 1993 VOL 15 NO 1