Abstract: In this paper the authors propose and verify an approach to control heat flow in machine tool components. Thermal deformations are a main aspect that affects the accuracy of machining. Due to goals of energy efficiency, thermal basic loads should be reduced. This leads to inhomogeneous and time variant temperature profiles. To counteract these negative consequences, material with high melting enthalpy is used as a method for thermal stabilization. The increased thermal capacity slows down the transient thermal behavior. To account for the delayed thermal equilibrium, a control mechanism for thermal flow is introduced. By varying a gap in a heat flow path the thermal resistance of an assembly can be controlled. This mechanism is evaluated in two experimental setups. First to validate the ability to control the thermal resistance and second to prove the possibility of a self-sufficient option based on the selfsensing abilities of thermal shape memory alloys.
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.
Abstract: Hexapod Machine Tool (HMT) is a parallel robot
mostly based on Stewart platform. Identification of kinematic
parameters of HMT is an important step of calibration procedure. In
this paper an algorithm is presented for identifying the kinematic
parameters of HMT using inverse kinematics error model. Based on
this algorithm, the calibration procedure is simulated. Measurement
configurations with maximum observability are decided as the first
step of this algorithm for a robust calibration. The errors occurring in
various configurations are illustrated graphically. It has been shown
that the boundaries of the workspace should be searched for the
maximum observability of errors. The importance of using
configurations with sufficient observability in calibrating hexapod
machine tools is verified by trial calibration with two different
groups of randomly selected configurations. One group is selected to
have sufficient observability and the other is in disregard of the
observability criterion. Simulation results confirm the validity of the
proposed identification algorithm.
Abstract: In this study, we experiment on precise control outlet
temperature of water from the water cooler with hot-gas bypass
method based on PI control logic for machine tool. Recently, technical
trend for machine tools is focused on enhancement of speed and
accuracy. High speedy processing causes thermal and structural
deformation of objects from the machine tools. Water cooler has to be
applied to machine tools to reduce the thermal negative influence with
accurate temperature controlling system. The goal of this study is to
minimize temperature error in steady state. In addition, control period
of an electronic expansion valve were considered to increment of
lifetime of the machine tools and quality of product with a water
cooler.