12ed11 - Advanced Machine Tool Design

12ED11 ADVANCED
MACHINE TOOL DESIGN

TOPICS:
STATIC AND DYNAMIC
STIFFNESS
S.BRADEESH MOORTHY, APME
INTRODUCTION
Machine tool design
It deals with the design considerations of the machine
components and the machine as a whole.
Machine tool structures
Components of machine tools such as beds, bases,
columns, box type housings, overarm, carriages,
tables etc .
Types of machine tool structures:
i. Beds and bases sub assemblies are mounted
ii. Housings individual units are assembled eg
speed box, spindle head
iii. Supporting and moving work piece / cutter
table, carriage, tailstock etc
Requirements & necessary conditions

for structures
Requirements
Mating surfaces to be machined with high degree
of accuracy for desired geometrical accuracy.
Geometrical accuracy to be maintained through
out the life of machine.
Provide safe operations and maintenance
Ensure stresses does not exceed safe limit.
Conditions
i. Proper material selection
ii. High static and dynamic stiffness
STATIC & DYNAMIC STIFFNESS

Machine tool and its cutting process can be expressed
by a closed loop.
Machine tool interacts with the cutting process.
Both machine tool and cutting process are
represented by their transfer functions.
If input to the machine (dP) is static then the output
(dY) is static in nature.
If the input to the machine (dP) is dynamic in nature
then the output (dY) is also dynamic in nature.
Designer should have good knowledge on the
cumulative static and dynamic characteristics of
machine tool as well as elements with which the
machine tool is made.
MACHINE TOOL CUTTING PROCESS

BLOCK DIAGRAM REPRESENTATION
p(t)
Machine tool transfer
function
Cutting process
transfer function
Y(t)
STATIC STIFFNESS
Behavior
of
element
(stiffness)under static conditions is
examined
from
its
forcedisplacement diagram.
Generally the relation is non-linear.
Generally the stiffness is measured
along the direction of the force.
If the stiffness is measured along
some other direction, it is called
cross stiffness.
Inverse of stiffness is compliance
which is normally used for
analyzing
static
behavior
of
machine elements.
Stiffness behavior of elements
affects parameters of machining
and quality of machined surface.
ASSESSMENT OF STATIC STIFFNESS

i. Static stiffness with
respect to work piece
accuracy
. Cross stiffness
represented by K = P/Y
P Resultant cutting force
between cutting tool and
work piece
Y relative displacement
normal to machined surface
. Higher K represents lesser
displacement perpendicular
to machined surface which
results in better accuracy.
Cont.
ii. Static stiffness with
respect to dynamic
stablity
. Cross stiffness represented by K
= P/Y
P Resultant cutting force
between cutting tool and work
piece
Y relative displacement normal
to surface of cut
. Y significant in chip thickness,
major role in machine tool
chatter.
REPRESENTATION OF STATIC
STIFFNESS
Every member undergoes deformation under load so it can

be considered as a spring.
Machine tool can be reduced into a combination of springs
in series or parallel.
Springs in series
Y Y1 Y2 Y3
1
1
1
1
C1 C 2 C 3
k
k1
k2
k3
Springs in parallel
k k1 k 2 k3 , y y1 y 2 y3
Example for series system
C C1.i12 2 .i223 .i32 4 C2 .i223 .i32 4 C3 .i32 4 C4
Gear transmission system with four shafts.

The total compliance for the machine tool is the summation
of reduced compliances
Compliance
Major contributor of C is C4, if all are speed reduction.
So compliance can be improved by improving the weak
element shaft 4.
Example for series system

k k1 k 2 k3 , y y1 y2 y3
If one spring contributes to
80% of stiffness and other
two remaining 20%.
Increasing stiffness of
stronger contributes to
increase in stiffness rather
than the other.
DYNAMIC
STIFFNESS
Dynamic loading causes dynamic displacement.
Sometimes for constant dynamic force response differs with
frequency of input.
The ratio Kdyn =Pdyn/ Ydyn is dynamic stiffness.
Dynamic and static stiffness relatedYby
dyn Yst . A
Where
A- magnification factor.
A depends on i) damping factor (ii) Frequency

ratio

n
If load is independent of frequency then
A1
2 2
If load is due to unbalanced force then
A2
1
2
VARIATION OF A WITH RESPECT TO
Cont..
From the graphs
A decreases if is increased
A is small if exciting frequency is away from natural
frequency
If is 0.25 - 2.5 then displacement under dynamic
condition is nearly equal to displacement in static
condition.
REPRESENTATION OF VIBRATION
BEHAVIOUR AND CONTROL
d2y
dy
mi 2 pi
ki y ki p
dt
dt
By solving n independent equations the

displacements are found out.
Resultant displacement y = y1 +y2+y3+ -----+yn
Dynamic compliance found out by y/P
In simple modes of vibration contribution of stiffness
of
elements is same in overall stiffness of machine
tool.
By increasing stiffness of elements overall stiffness
can be increased.
Highest among the natural frequency should desirably
be 2.5 times less than the highest excitation
frequency.
Lowest among the natural frequency should desirably
be 2.5 times greater than the lowest excitation

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12ED11 ADVANCED

MACHINE TOOL DESIGN

S.BRADEESH MOORTHY, APME

Requirements & necessary conditions

STATIC & DYNAMIC STIFFNESS

MACHINE TOOL CUTTING PROCESS

ASSESSMENT OF STATIC STIFFNESS

Every member undergoes deformation under load so it can

Example for series system

C C1.i12 2 .i223 .i32 4 C2 .i223 .i32 4 C3 .i32 4 C4

Gear transmission system with four shafts.

Example for series system

A depends on i) damping factor (ii) Frequency

VARIATION OF A WITH RESPECT TO

By solving n independent equations the

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