Dynamic Interaction Between Precision Machine Tools and Their Foundations

The manufacturing accuracy of modern machine tools strongly depends on the placement of the machine tool structure on the factory’s foundation. Civil engineering knows a variety of foundation types and factory planners must carefully consider local circumstances such as the size and the properties of the regional subsoil as well as the individual requirements of machine tools. Two of the major reasons for the effect of the foundation onto the machining accuracy are the added stiffness and the increased mass from the installation site’s foundation. A change of these characteristics greatly affects the dynamic characteristics of the overall machine tool and therefore also the machining dynamics. Although some general rules and guidelines exist for the design of foundations, their dynamic interaction with the supported precision machine tool structures is not well understood yet. This paper presents a series of measurements on two different types of machine tool foundations and highlights the characteristic differences in their dynamic interaction. It also proposes a novel approach to validate the conclusions with the use of foundation and machine tool scale models. These results can serve factory planners of precision targeting shop floors as a valuable guide for deciding on a suitable foundation for lowering the individual machine tool vibrations and/or reducing the dynamic interaction between closely located machine tools.

Stiffness and Damping of Epoxy Granite

The productivity and accuracy of machine tools now became most significant as the cutting conditions changes continuously. Therefore to withstand against these cutting conditions the machine tool structural material must have higher stiffness and damping. This review deals with various research works to study the stiffness and damping of epoxy granite or polymer concrete. It is reported that the epoxy granite shows improved damping and high strength to weight ratio than that of conventional machine tool structures of steel and cast iron.

Static and dynamic behavior of steel-reinforced epoxy granite CNC lathe bed using finite element analysis

Machine tools are used to manufacture components with desired size, shape, and surface finish. The accuracy of machining is influenced by stiffness, structural damping, and long-term dimensional stability of the machine tool structures. Components machined using such machines exhibit more dimensional variations because of the excessive vibration during machining at higher speeds. Compared to conventional materials like cast iron, stone-based polymer composites such as epoxy granite have been found to provide improved damping characteristics, by seven to ten folds, due to which they are being considered for machine tool structures as alternate materials. The stiffness of structures made of epoxy granite can be enhanced by reinforcing with structural steel. The current work highlights the design and analysis of different steel reinforcements in the lathe bed made of the epoxy granite composite to achieve equivalent stiffness to that of cast iron bed for improved static and dynamic performances of the CNC lathe. A finite element model of the existing the cast iron bed was developed to evaluate the static (torsional rigidity) and dynamic characteristics (natural frequency) and the results were validated using the experimental results. Then finite element models of five different steel reinforcement designs of the epoxy granite bed were developed, and their static and dynamic behaviors were compared with the cast iron bed through numerical simulation using finite element analysis. The proposed design (Design-5) of the epoxy granite bed is found to have an improvement in dynamic characteristics by 4–10% with improved stiffness and offers a mass reduction of 22% compared to the cast iron bed, hence it can be used for the manufacture of the CNC lathe bed and other machine tool structures for enhanced performance.

Design and analysis of epoxy granite vertical machining centre base for improved static and dynamic characteristics

The structural vibration in conventional machine tools which are generally made of cast iron may lead to poor surface finish of the machined components. This has led to the investigations on alternative materials for machine tool structures such as concrete, polymer concrete and epoxy granite which have higher damping properties but lesser Young's modulus. However, higher static stiffness with higher damping is essential for improving the static and dynamic characteristics of machine tool structures. Hence, this work focuses on replacing the vertical machining centre base made of cast iron with steel reinforced epoxy granite to improve the structural static stiffness. A finite element model of the above base is developed and validated against the experimental data obtained using modal analysis. The validated numerical approach is applied for investigating the seven progressive design configurations of base reinforced with steel. It is found that the epoxy granite base of Design configuration-7 with L-channels has significantly reduced the deformation by 56 and 36% considering milling and drilling operations, respectively, in comparison to cast iron base. Further, the natural frequencies of the above configuration are higher in all the modes (by more than 50%) under consideration than those of the existing cast iron structure. Therefore, the proposed configuration of base is a viable alternative for the existing base in order to achieve higher structural damping. The novelty of the present work is the design of epoxy granite vertical machining centre base using steel reinforcements to improve structural rigidity with ease of manufacturing.

Energy - Information Regularities of Increasing Productivity in Metalworking Machine Tools

Increasing productivity by higher cutting speed and achieving high precision of machined products at the same time is an important trend in the development of manufacturing technologies and metalworking machine tools. If the traditional method of exchangeable components in assemblies will lead to inefficient precise processes, the product costs will increase. The proposed energy-informational model considers a procedural system establishing the ratio of the cutting speed and the speed of physical processes in the machine tools. The energetic limit for the attainability of associated processes describes the allowable speed of materials processing by the machine tools. Stiffness of machine tool structures for highest precision manufacturing becomes comparable to work piece geometrical accuracy and manufacturing process tolerances. This paper gives several examples for admissible limits of increased productivity by increased process speeds in various manufacturing technologies for both traditional cutting and innovative methods.