scholarly journals Development of a vibration free machine structure for high-speed micro-milling center

2021 ◽  
Author(s):  
Arnab Das ◽  
Shashank Shukla ◽  
Mohan Kumar ◽  
Chitransh Singh ◽  
Madan Lal Chandravanshi ◽  
...  
Keyword(s):  
Machine Tool ◽  
Surface Finish ◽  
Machine Tools ◽  
High Speed ◽  
Micro Milling ◽  
High Speed Machining ◽  
Element Analysis ◽  
Dimensional Precision ◽  
Ultra Precision ◽  
Machine Structure

Abstract The demand of ultra-precision micro-machine tools is growing day by day due to exigent requirements of miniaturized components. High accuracy, good dimensional precision and smooth surface finish are the major characteristics of these ultra-precision machine tools. High-speed machining has been adopted to increase the productivity using high-speed spindles. However, machine tool vibration is a major issue in high-speed machining. Vibration significantly deteriorates the quality of micro-machining in terms of dimensional precision and surface finish. This paper describes a design methodology of a closed type machine structure for vibration minimization of a high-speed micro-milling center. The rigid machine structure has provided plenty of stiffness and the damping capability to the machine tool without utilizing vibration absorbers . The models of the machine structures have been generated and assembled in AutoCAD 3D . The performances of the integrated micro-milling machine tools were determined by finite element analysis. The best model has been selected and proposed for manufacturing. Additionally, simulation results were validated by comparing with experimental results. Eventually, after manufacturing and assembly, experiments have been performed and determined that the amplitude of vibration was approaching towards nanometer level throughout the working range of the high-speed spindle. The machine tool was capable to fabricate miniaturized components with fine surface finish.

Optimized Design and Performance Study of High Speed Five-Axis Machine Tools

2020 ◽  
Author(s):  
Tzu-Chi Chan ◽  
Jyun-Sian Yang
Keyword(s):  
Machine Tool ◽  
Dynamic Characteristics ◽  
Machine Tools ◽  
High Speed ◽  
Spectral Response ◽  
Work Piece ◽  
Static And Dynamic Characteristics ◽  
Five Axis ◽  
Speed Accuracy ◽  
Machine Structure

Abstract With the development of machine tools trending toward high precision, intelligence, multi-axis, and high speed, the improvement of the processing performance and rigidity of the machine is considerably important. The objective of this study is to design of a high-speed five-axis moving-column machine tool and perform structural analysis and optimization. We study the static and dynamic characteristics of the five-axis machine tool, design and improve the mechanical structure, and optimize the structural configuration of the machine. The entire machine structure is further analyzed and enhanced to improve its static and dynamic characteristics, including static rigidity, modal, transient, and spectral response characteristics. The static and dynamic characteristics of the machine structure directly affect the machine processing performance, and further affect the work piece precision machined by the tool. Through this study, the design technology for speed, accuracy, and surface roughness of the machine tool are further improved.

scholarly journals Effect of Time-Varying Moving Structures on the Spatial Accuracy of Five-Axis Machine Tools

2021 ◽  
Author(s):  
Tzu-Chi Chan ◽  
Jyun-Sian Yang
Keyword(s):  
Machine Tool ◽  
Dynamic Characteristics ◽  
Machine Tools ◽  
High Speed ◽  
Time Varying ◽  
Spatial Accuracy ◽  
Static And Dynamic Characteristics ◽  
Five Axis ◽  
Speed Accuracy ◽  
Machine Structure

Abstract Machine tools are constantly in motion during machining; however, studies have not considered the effect of the dynamic and static characteristics of the machine caused by the movement of the structure over time. In this study, the time-varying moving structure in the spatial coordinate arm is analyzed to improve the spatial accuracy of the motion of a five-axis machine tool in the cutting area. The objective is to design a high-speed five-axis moving-column machine tool and to perform structural analysis of spatial accuracy. We studied the static and dynamic characteristics of a five-axis machine tool, designed and improved its mechanical structure, and optimized its structural configuration. With further analysis, the entire machine structure was enhanced to improve its static and dynamic characteristics. The static and dynamic characteristics of the machine structure were found to directly affect its processing performance and the precision of the workpiece machined by the tool. Through this study, the design technology for speed, accuracy, and surface roughness of the machine tool was further improved.

Research on MFBD Modeling Method for a Gantry Machining Center Beam Components

2011 ◽  
Vol 188 ◽  
pp. 487-492 ◽  
Author(s):  
Q.J. Yang ◽  
D.N. Li ◽  
L.L. Kong ◽  
K. Li
Keyword(s):  
Machine Tool ◽  
Machine Tools ◽  
High Speed ◽  
Modeling Method ◽  
Ball Screw ◽  
Machining Processes ◽  
Element Analysis ◽  
Machining Center ◽  
Body Dynamics ◽  
Multi Body

In modern machining processes, Gantry Machining Center is one of the most important machine tools. Moreover, beam components directly relate to the overall performance. From multi-body simulation (MBS) and finite element analysis (FEA) respectively, the paper discusses current state of the multi-body dynamics modelling of the machine tool components in domestic and overseas. In this paper, We adopt a method, the multi-flexible body dynamics(MFBD) modeling method for machine tool transmission components (linear guidance and ball screw drives) in software Recurdyn, to create the conditions for MFBD simulation analysis of the beam components system. Much more, it provides a way of MFBD modelling for machine tools components in both the high-speed and high-performance.

A Parallely Actuated Work Support Module for Reconfigurable Machining Systems

1998 ◽  
Author(s):  
Venkat Gopalakrishnan ◽  
Sridhar Kota
Keyword(s):  
Machine Tool ◽  
Machine Tools ◽  
Degrees Of Freedom ◽  
Mechanical Design ◽  
Performance Criteria ◽  
Machining Accuracy ◽  
Parallel Mechanisms ◽  
Element Analysis ◽  
Work Support ◽  
Reconfigurable Machining

Abstract In order to respond quickly to changes in market demands and the resulting product design changes, machine tool manufacturers must reduce the machine tool design lead time and machine set-up time. Reconfigurable Machine Tools (RMTs), assembled from machine modules such as spindles, slides and worktables are designed to be easily reconfigured to accommodate new machining requirements. The essential characteristics of RMTs are modularity, flexibility, convertibility and cost effectiveness. The goal of Reconfigurable Machining Systems (RMSs), composed of RMTs and other types of machines, is to provide exactly the capacity and functionality, exactly when needed. The scope of RMSs design includes mechanical hardware, control systems, process planning and tooling. One of the key challenges in the mechanical design of reconfigurable machine tools is to achieve the desired machining accuracy in all intended machine configurations. To meet this challenge we propose (a) to distribute the total number of degrees of freedom between the work-support and the tool and (b) employ parallely-actuated mechanisms for stiffness and ease of reconfigurability. In this paper we present a novel parallely-actuated work-support module as a part of an RMT. Following a brief summary of a few parallel mechanisms used in machine tool applications, this paper presents a three-degree-of-freedom work-support module designed to meet the machining requirements of specific features on a family of automotive cylinder heads. Inverse kinematics, dynamic and finite element analysis are performed to verify the performance criteria such as workspace envelope and rigidity. A prototype of the proposed module is also presented.

Design and Analysis of Fluidless Cooling Devices for High Speed Machining

1995 ◽  
Author(s):  
Samir B. Billatos ◽  
Nadia A. Basaly
Keyword(s):  
High Speed ◽  
Surface Characteristics ◽  
Work Piece ◽  
High Speed Machining ◽  
Element Analysis ◽  
New Approach ◽  
Cycle System ◽  
Increase Production Cost ◽  
Harmful Effects ◽  
Interface Heat

Abstract In high speed machining, the generated heat produces very high temperatures at the tool-work interface. Heat generated at the cutting area may shorten tool life, damage work piece surface, affect surface characteristics, and hence increase production cost. To deal with these problems, cutting fluids are used. Unfortunately, these fluids cause harmful effects to the operators and serious problems of pollution to the environment. Therefore, a new approach is developed to reduce the cutting tool temperature without using external coolants, and thus considerably reduce the amount of the hazardous waste being disposed to the environment. It removes a portion of the generated heat from the tool-work interface by flowing water in a closed cooling cycle system. The approach was analyzed and verified using Finite Element Analysis. Results were compared to the dry and wet cutting cases obtained from literature, and it was found that temperatures on the flank and rake faces of the tool can be lowered, and the overheated area of the tool tip, and consequently its wear, can be reduced significantly.

Research on Modal Analysis of Precision Micro Slitting Turn-Milling Machine Tool Based on Hammer Experimental Method

2019 ◽  
Vol 295 ◽  
pp. 67-72
Author(s):  
Zhong Peng Zheng ◽  
Xin Yang Jiang ◽  
Xin Jin
Keyword(s):  
Machine Tool ◽  
Modal Analysis ◽  
Experimental Method ◽  
Machine Tools ◽  
Processing Parameters ◽  
Milling Machine ◽  
Vibration Model ◽  
Vibration Modal ◽  
Turn Milling ◽  
Machine Structure

In order to improve the dynamic stability of precision micro slitting turn-milling machine tools, reduce or avoid the vibration problem during the cutting process, optimize the machine structure and processing parameters, the modal analysis of precision micro slitting turn-milling machine tool based on hammer experimental method was researched. In this paper, by analyzing the mechanism of precision micro slitting turn-milling machine tools, the multi degree-of-freedom mathematical vibration model of precision slitting turn-milling machine tools is constructed. The precision micro turn-milling machine tool is analyzed based on the hammer experiment analysis. The modal analysis obtained the first five natural frequencies and resonance speeds of the precision micro slitting turn-milling machine tool,including ST26, NN-25UB8K2 and NN-20UB87. The research results show that hammer experimental method can evaluate the vibration modal analysis of precision micro slitting turn-milling machine tools to some extent. The experimental modal analysis results guide and optimize the structural design and processing technology of precision micro slitting turn-milling machine tools.

A Technique for Enhancing Machine Tool Accuracy by Transferring the Metrology Reference From the Machine Tool to the Workpiece

2006 ◽  
Vol 129 (3) ◽  
pp. 636-643 ◽  
Author(s):  
Bethany A. Woody ◽  
K. Scott Smith ◽  
Robert J. Hocken ◽  
Jimmie A. Miller
Keyword(s):  
Machine Tool ◽  
Machine Tools ◽  
High Speed ◽  
Large Scale ◽  
Thermal Environment ◽  
Coordinate Measuring Machine ◽  
Shop Floor ◽  
Finished Part ◽  
Measuring Machine ◽  
Monolithic Components

High-speed machining (HSM) has had a large impact on the design and fabrication of aerospace parts and HSM techniques have been used to improve the quality of conventionally machined parts as well. Initially, the trend toward HSM of monolithic parts was focused on small parts, where existing machine tools have sufficient precision to machine the required features. But, as the technology continues to progress, the scale of monolithic parts has continued to grow. However, the growth of such parts has become limited by the inability of existing machines to achieve the tolerances required for assembly due to the long-range accuracy and the thermal environment of most machine tools. Increasing part size without decreasing the tolerances using existing technology requires very large and very accurate machines in a tightly controlled thermal environment. As a result, new techniques are needed to precisely and accurately manufacture large scale monolithic components. Previous work has established the fiducial calibration system (FCS), a technique, which, for the first time provides a method that allows for the accuracy of a coordinate measuring machine (CMM) to be transferred to the shop floor. This paper addresses the range of applicability of the FCS, and provides a method to answer two fundamental questions. First, given a set of machines and fiducials, how much improvement in precision of the finished part can be expected? And second, given a desired precision of the finished part, what machines and fiducials are required? The achievable improvement in precision using the FCS depends on a number of factors including, but not limited to: the type of fiducial, the probing system on the machine and CMM, the time required to make a measurement, and the frequency of measurement. In this paper, the sensitivity of the method to such items is evaluated through an uncertainty analysis, and examples are given indicating how this analysis can be used in a variety of cases.

Design of Special Fixture for Micro High Speed Motorized Spindle

2011 ◽  
Vol 228-229 ◽  
pp. 66-71
Author(s):  
Xiao Hong Lu ◽  
Zhen Yuan Jia ◽  
Zhi Cong Zhang ◽  
Xv Jia
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
High Speed ◽  
Micro Milling ◽  
Machining Accuracy ◽  
Milling Machine ◽  
Cnc Milling ◽  
Analysis Method ◽  
Motorized Spindle ◽  
Element Analysis

The fixture of motorized spindle significantly affect the vibration of micro high speed CNC milling machine, its performance can directly affect the machining accuracy of the entire micro milling machine. A special fixture of high-speed motorized spindle is designed in the paper and its static characteristics are checked by utilizing ANSYS finite element analysis software. To guarantee the sufficient strength of bolts and the safety of motorized spindle when the motorized spindle runs at high speed, theory analysis method and ANSYS finite element analysis method are used to make the strength check of the fixture. The designed special fixture for high speed motorized spindle plays an important part in the design of high-speed motorized spindle.

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