Abstract: Large-scale machine tools for the manufacturing of
large work pieces, e.g. blades, casings or gears for wind turbines,
feature pose-dependent dynamic behavior. Small structural damping
coefficients lead to long decay times for structural vibrations that
have negative impacts on the production process. Typically, these
vibrations are handled by increasing the stiffness of the structure by
adding mass. This is counterproductive to the needs of sustainable
manufacturing as it leads to higher resource consumption both in
material and in energy. Recent research activities have led to higher
resource efficiency by radical mass reduction that is based on controlintegrated
active vibration avoidance and damping methods. These
control methods depend on information describing the dynamic
behavior of the controlled machine tools in order to tune the
avoidance or reduction method parameters according to the current
state of the machine. This paper presents the appearance, consequences and challenges
of the pose-dependent dynamic behavior of lightweight large-scale
machine tool structures in production. It starts with the theoretical
introduction of the challenges of lightweight machine tool structures
resulting from reduced stiffness. The statement of the pose-dependent
dynamic behavior is corroborated by the results of the experimental
modal analysis of a lightweight test structure. Afterwards, the
consequences of the pose-dependent dynamic behavior of lightweight
machine tool structures for the use of active control and vibration
reduction methods are explained. Based on the state of the art of
pose-dependent dynamic machine tool models and the modal
investigation of an FE-model of the lightweight test structure, the
criteria for a pose-dependent model for use in vibration reduction are
derived. The description of the approach for a general posedependent
model of the dynamic behavior of large lightweight
machine tools that provides the necessary input to the aforementioned
vibration avoidance and reduction methods to properly tackle
machine vibrations is the outlook of the paper.
Abstract: The performance of a machine tool is eventually assessed by its ability to produce a component of the required geometry in minimum time and at small operating cost. It is customary to base the structural design of any machine tool primarily upon the requirements of static rigidity and minimum natural frequency of vibration. The operating properties of machines like cutting speed, feed and depth of cut as well as the size of the work piece also have to be kept in mind by a machine tool structural designer. This paper presents a novel approach to the design of machine tool column for static and dynamic rigidity requirement. Model evaluation is done effectively through use of General Finite Element Analysis software ANSYS. Studies on machine tool column are used to illustrate finite element based concept evaluation technique. This paper also presents results obtained from the computations of thin walled box type columns that are subjected to torsional and bending loads in case of static analysis and also results from modal analysis. The columns analyzed are square and rectangle based tapered open column, column with cover plate, horizontal partitions and with apertures. For the analysis purpose a total of 70 columns were analyzed for bending, torsional and modal analysis. In this study it is observed that the orientation and aspect ratio of apertures have no significant effect on the static and dynamic rigidity of the machine tool structure.
Abstract: Chatter vibration has been a troublesome problem
for a machine tool toward the high precision and high speed machining.
Essentially, the machining performance is determined by the dynamic
characteristics of the machine tool structure and dynamics of cutting
process, which can further be identified in terms of the stability lobe
diagram. Therefore, realization on the machine tool dynamic behavior
can help to enhance the cutting stability. To assess the dynamic
characteristics and machining stability of a vertical milling system
under the influence of a linear guide, this study developed a finite
element model integrated the modeling of linear components with the
implementation of contact stiffness at the rolling interface. Both the
finite element simulations and experimental measurements reveal that
the linear guide with different preload greatly affects the vibration
behavior and milling stability of the vertical column spindle head
system, which also clearly indicate that the predictions of the
machining stability agree well with the cutting tests. It is believed that
the proposed model can be successfully applied to evaluate the
dynamics performance of machine tool systems of various
configurations.
Abstract: Chatter vibration has been a troublesome problem for a
machine tool toward the high precision and high speed machining.
Essentially, the machining performance is determined by the dynamic
characteristics of the machine tool structure and dynamics of cutting
process. Therefore the dynamic vibration behavior of spindle tool
system greatly determines the performance of machine tool. The
purpose of this study is to investigate the influences of the machine
frame structure on the dynamic frequency of spindle tool unit through
finite element modeling approach. To this end, a realistic finite
element model of the vertical milling system was created by
incorporated the spindle-bearing model into the spindle head stock of
the machine frame. Using this model, the dynamic characteristics of
the milling machines with different structural designs of spindle head
stock and identical spindle tool unit were demonstrated. The results of
the finite element modeling reveal that the spindle tool unit behaves
more compliant when the excited frequency approaches the natural
mode of the spindle tool; while the spindle tool show a higher dynamic
stiffness at lower frequency that may be initiated by the structural
mode of milling head. Under this condition, it is concluded that the
structural configuration of spindle head stock associated with the
vertical column of milling machine plays an important role in
determining the machining dynamics of the spindle unit.