Abstract
Static and dynamic properties of machine tools have a decisive influence on their accuracy. In case of HSM machine tools, the phenomena associated with them are additionally strengthened by high machining parameters. In order to predict a machine tool behaviour at the design stage, it is necessary to use numerical methods to simulate for its simulation. Thanks to the use of this type of software, it is possible to perform the next step, i.e. the optimisation of the structure. In case of machine tools, due to the multiplicity of factors affecting its accuracy, this should be a multicriterial optimisation. This article presents the results of a vertical milling centre spindle body optimisation using the Finite Element Method. The results of static stiffness and vibration frequency analysis for three bodies (i.e. the body of the form and dimensions proposed by the constructor, the body after parametric optimisation and the body after the form and parametric optimisation including use of different materials) were compared. The optimisation tools available in the ANSYS system were used for the simulation. The calculations were preceded by experimental research and modifications of dynamic parameters performed on their basis using the author's methodology to determine the behaviour of a partially existing structure for different masses of the body being optimised.
Highlights
The continuous development of technology presents new solutions while dictating new development trends
The still valid approach based on the use of constructional solutions from already produced machine tools of conventional work parameters should be changed into a design process considering the possibilities offered by Finite Element Method (FEM) simulations in the field of thermomechanical, mechanical and flow analysis and optimisation
As a result of the parametric optimisation of the headstock, three dimensions of the body were proposed. They are characterised by varying degrees of mass reduction with the simultaneous decrease in static stiffness prevailing in these three cases
Summary
The continuous development of technology presents new solutions while dictating new development trends. In order to reduce the consumption of structural materials weight and emissions of harmful chemicals into the atmosphere, combined with and constantly growing economic demands of the market regarding achieved accuracy of dimensionally shaped workpieces and achieved cutting speeds become a major factor driving the need to develop and introduce innovative solutions in the field of optimal design of machine tool bodies. A significant change in the operating parameters of such machine tools results in enhancement of phenomena, which earlier were not so important in case of machines characterised by "conventional parameters". This applies to, among others, an increase in the power of heat sources, such as feed motors and integrated main propulsion engines in form of electro-spindles, bearing nodes, helical-wheel transmissions in classical drives and linear motors. The still valid approach based on the use of constructional solutions from already produced machine tools of conventional work parameters should be changed into a design process considering the possibilities offered by FEM simulations in the field of thermomechanical, mechanical and flow analysis and optimisation
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