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Abstract
In this study, it used a vertical machining center as the study object, conducted finite-element simulations and experimental research on its thermal performance, analyzed the weaknesses affecting the thermal performance of the machine tool, and proposed a machine tool thermal performance analysis method by combining structure optimization based on the headstock thermal characteristics and the temperature field control. Without changing the machine tool’s heating power and static and dynamic stiffness, on the one hand, the design theory of the thermal plane of symmetry was used to reconstruct the headstock into a symmetrical structure such that the thermal deformations could be mutually coupled and offset each other. On the other hand, cooling troughs were designed on both sides and the front of the headstock so that cooling control could be arranged for the headstock by optimizing the layout and the width/depth of the cooling troughs. Therefore, the whole-machine temperature elevation and thermal deformation can be reduced. Based on the heat transfer analysis of the cooling troughs, it constructed a thermal performance finite-element simulation model and compared the temperature and whole-machine thermal deformation on several critical points before and after the reconstruction. Finally, the experimental measurements of the thermal performance were obtained using the prototype designed and manufactured based on the optimization results. It was verified that the thermal performance of the vertical machining center was greatly improved by comparing the simulation results with the experimental results.DOI: http://dx.doi.org/10.5755/j01.mech.19.4.5044
Highlights
The influence of errors imposed on workpiece by thermal deformation of machine tools has attracted wide attention
The thermal deformation generated between the spindle and the workbench caused by thermal expansion can mutually cancel each other, resulting in reduced thermal error and improved machining precision
Based on the weakness analyses of the machine tool thermal performance and for the purposes of minimizing the cost, we proposed the following thermal structure design and reconstruction scheme: 1) Install a cooling fan on top of the spindle motor to reduce the heat transfer from the motor to the headstock and at the same time perform forced cooling on the spindle motor and headstock
Summary
The influence of errors imposed on workpiece by thermal deformation of machine tools has attracted wide attention. Studies have shown that 40–70% of the error in precision machining arises from thermal error [1,2,3] It has become one of the most important research topics to fully consider the thermal performance optimized design in the machine tool design stage and to improve the machining precision. The finiteelement method is one of the main approaches for complex-structure machine tool thermal performance analysis and structural optimization research [4] It is a method to improve machining precision during the cutting process after the machine tool design and manufacture are finished The implementation of this method includes using experimental measurements on machine tool thermal deformation and temperature fields at the early stage, building the thermal deformation model using mathematical methods, and performing real-time compensation using NC programs. Thermal performance weakness analysis and reconstruction scheme of a machine tool headstock
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