Dynamic performance enhancement of machining center with epoxy granite base: Experiments and finite element simulations

Abstract

Epoxy granite (EG) is used for machine building applications owing to excellent dynamic properties compared to cast iron (CI). Steel is preferred to reinforce with EG to improve the static stiffness of structures. The effects of addition of steel content on stiffness and damping properties of EG composite were assessed through a specimen level study. Subsequently, the base, which is a primary structure that affects the dynamics of the vertical machining center (VMC) was taken up for investigation. The novelty of the present work is the development of scaled down model of EG base with optimum reinforcement ratio to improve the dynamic response of VMC without compromising the static rigidity of the existing CI base. An experimental study was carried out to validate the assumption made in numerical analysis that EG is isotropic and homogeneous. The results of similitude relations revealed that the EG base exhibited sixteen times higher damping compared to CI base. The influence of EG base on the overall dynamics of VMC was assessed by performing pre-stressed finite element modal analysis and harmonic analysis. Upto seven-fold improvements in directional stiffnesses of VMC with the EG base were observed compared to VMC with CI base. The results of stability lobe diagram revealed a three-fold improvement in material removal rate for VMC with EG base compared to VMC with CI base. Thus, the proposed steel reinforced configuration of EG base has demonstrated a better dynamic performance of VMC without compromising static rigidity.