Abstract
Abstract The preliminary design stage ensures to evaluate machine tool performances according to the simulation of reduced models. Performance criteria are defined regarding the attempted machining process requirements. In our case, we study the problem of machine tool design for hard metal cutting, where a high level of stiffness is required. In this context, this paper’s aim is to introduce a new methodology of machine tool architectures modeling, optimization, and selection with regards to their stiffness and dynamic performances at the preliminary design stage. However, this type of study requires a quantitative evaluation of performance indicators. Studied machine tool structures are modelled with simplified shape parts. The dimensions of these parts are defined as design variables. Afterward, for each considered architecture, parametric design optimization is performed to minimize its mass under the constraint of a minimal attempted stiffness all over the workspace. This approach allowed restricting the total number of machine tool architectures to be detailed further and analyzed more accurately. In a first time, the paper includes an illustration of the developed methodology through an example of machine tool architecture evaluation and optimization. In a second time, the method is used to compare different kinds of machine tool architectures regarding their ability to be light for an attempted stiffness.
Highlights
Performance requirements for machine tools have evolved significantly over the past decade
To develop predictive and fast models for the evaluation and the optimization of several machine tool architectures, in the preliminary design stage, we propose, in this work, a reduced finite element model (FEM) approach to simplify model definition
Our methodology is applied to several closedloop machine tool architectures for a workspace size of (z = 2 m, y = 2 m) and with the same values of ξmax and ξmin (Fig. 14)
Summary
Performance requirements for machine tools have evolved significantly over the past decade. Productivity and quality requirements for hard material parts have increased considerably. This evolution is mainly due to the expansion of titanium alloys used in the aeronautical industry (Inagaki, Takechi, Shirai, & Ariyasu, 2014; Rodrigues Henriques, de Campos, Alves Cairo, & Bressiani, 2005). Titanium alloys are widely used for structural aeronautical components to optimize the performance in terms of mass, corrosion resistance, and mechanical behavior (Inagaki et al, 2014; Wagner, 2011). Low cutting speeds and high cutting forces characterize titanium alloys machining (Wagner, 2011). High cutting forces coupled with low rotational frequencies of the spindle can produce large deflections of the machine tool structure. Static behavior must be controlled during the design stage (Huo & Cheng, 2009; Maj, Modica, & Bianchi, 2006; Mori, Piner, Ding, & Hansel, 2008)
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