CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

3
DESIGN OF MACHINE TOOL STRUCTURE AND
ANALYSIS
3.1 Introduction
Beds, bases, columns and box type housings are called structures in machine
tools. In machine tools, 70-90% of the total weight of the machine is due to the weight of
the structure [3]. In this chapter classification and functions of machine tool structure is
described. Researchers [7, 9] have worked with different types of materials like cast iron,
mild steel, granite and epoxy concrete for machine tool structure for different
applications. Profile of the machine tool and selection of different stiffeners/ribs are
suggested by researchers. Quality of the job produced on these machine tools depends
directly on the quality and performance of machine tools. To develop good products,
design engineers need to study how their designs will behave in real-world conditions.

The limitations of physical model techniques have led to the development of

mathematical models representing a variety of mechanical structures. As in this approach,
whole structure is divided into finite elements, it is known as Finite Element Analysis.
The FEA is a very useful tool in engineering today and same has proved to be an
important technique in machine tool structural analysis. Thus, Computer is an invaluable
tool for a designer in his task for evaluating alternative designs to arrive at the optimum
design and also predicting the static, dynamic and thermal behavior of the machine before
arriving at the final design.

3.2 Functions of Machine Tool Structure and Their Requirements

Machine tool parts, such as beds, bases, columns, box-type housings, over arms,
carriages, table etc. are known as structures. Basic functions of machine tool structure are
as follows:

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

a) To provide rigid support on which various subassemblies can be mounted i.e. beds,
bases.
b) To provide housings for individual units or their assemblies like s gear box, spindle
head.
c) To support and move the work piece and tool relatively, i.e. table, carriage, tail stock
etc.

Machine tool structures must satisfy the following requirements:

a) All important mating surface of the structures should be machined with a high degree
of accuracy to provide the desired geometrical accuracy;
b) The initial geometrical accuracy of the structures should be maintained during the
whole service life of the machine tool; and
c) The shapes and sizes of the structures should not only provide safe operation and
maintenance of the machine tool but also ensure that working stresses and
deformations do not exceed specific limits; it should be noted that the stresses and
deformations are due to mechanical as well as thermal loading.
d) Efficient thermal control on machine element such as spindle, ball screw and
bearings for better part accuracy.
e) Faster tool change system.
f) Very high rapid traverse rates of round 40-60 m/min for faster tool positioning and
very high cutting feed rates for increased metal removal rates.

The design features that provide for ease of manufacture, maintenance, etc. are
peculiar to each structure and will, therefore, be discussed separately for different
structures. However, there are two common features, which are fundamental to the
satisfactory fulfillment of above requirements for all structures. These are:

1. Proper selection of material.

2. High static and dynamic stiffness.[23]

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

3.3 Classification of Machine Tool Structure

Classification of machine tool structures which can be subdivided by various

characteristics into the following groups:

a) By purpose into:
1. Beds, frameworks, carrying bodies.
2. Bases, bedplates etc.
3. Housing, boxes, columns, pillar, brackets.
4. Castings and covers.

b) By the method of manufacture into:

1. Cast.
2. Welded.
3. Combined cast and welded.

c) By functions they perform:

1. Beds and bases, upon which the various subassemblies are mounted.
2. Box type housings in which individual units are assembled.
3. Parts those serve for supporting and moving work piece and tool i.e. table,
carriage etc.

3.4 Materials of Machine Tool Structure

The structure of a machine tool forms the vital link between the cutting tool and
work piece on a metal cutting machine. The machine tools metal removal rate, accuracy,
overall cost, method of production and lead times, depend upon the type of structural
material and its properties.

The commonly used materials for machine tool structures are cast iron and steel.
While in some applications Granite and Epoxy Concrete, newly developed material, is
also introduced. Cast iron structures were almost exclusively used in machine tools till a
decade or so ago, but lately welded steel structures are finding wider application due to
advances in welding technology. The choice of whether the structure should be made
from cast iron or steel depends upon a number of factors, which are discussed as follows:

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

3.4.1 Material Properties

Important material properties of relevance are as under:

Modulus of elasticity: For high stiffness it is necessary to choose materials with a

high value of E. For instance, the high strength nodular graphite cast iron has
doubled the modulus of elasticity than the normal cast iron, apart from its high
internal damping. All steels have practically the same E and therefore mostly the
non-expensive good commercial quality steel is used for machine tool structures.

Specific stiffness: Material should have high specific stiffness.

Damping: Cast iron has higher inherent damping properties, damping in steel
structures occurs mainly in welds, if welded joints are properly designed, the
damping of steel structure may approach that of cast iron.

Long-term dimensional stability: The machine tool structural material must also
have a good long-term dimensional stability. Locked in stress levels should be
reduced to as close to zero as possible to achieve this.

Coolant resistance: The material should be unaffected by coolant.

Wear rate and frictional properties: Material should have low wear rate and low
coefficient of friction.

Thermal expansion coefficient: The material used should have a reasonably low
coefficient of expansion. If several composite materials are used, each should have
the same coefficient of expansion to avoid thermal bending/distortion. [7]

3.4.2 Different Materials Used for machine tool structure

As already stated, commonly used materials for machine tool structure are cast
iron and steel. While in recent times, granite and epoxy concrete are also developed and
used for structures. These materials are discussed here:

1. Cast Iron: From early times cast iron has been the most commonly used material for
machine tool structures. It may be cast into complex and intricate shapes. It is easily

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

machined and may be hand-scraped and lapped to a high degree of accuracy. It has
fairly good damping properties and also has reasonably good antifriction properties
helped by the graphite contained in it. It can be given very good long-term
dimensional stability by giving it a special long cycle stress relief annealing
treatment. Cast iron should be preferred for complex structures subjected to normal
loading, when these structures are to be made large in numbers.

It does, however, have several disadvantages. One major disadvantage is the time
and cost taken to produce a finished casting. Again care has to be taken at design
stage to ensure no abrupt changes in section thickness. Most manufacturing stages
involve the moving of the component either in or outside the factory. Typical
physical properties are given in the table.

2. Mild steel weldments: since 1950s mild steel weldments have been used more and
more as a machine tool structural material. They have a high stiffness and the
strength is also high. Values of properties of steel are listed in table. It has lower
weight compare to cast iron. If necessary, in mild steel structures thin wall sections
can be used. While with cast iron the wall thickness is limited by the accuracy of
casting. Steel should be preferred for simple, heavily loaded structures, which are to
be manufactured in small numbers; this is due to the fact that in lightly loaded
structures the higher mechanical properties of steel cannot be fully exploited.

This material too has some disadvantages. The material damping is low and mild
steel weldments have a marked tendency to ring. Friction points are sometimes
built-in friction is high and cast iron or plastic insets have to be used to reduce
friction to avoid pick-up. Again for this material, manufacturing times are long.
This material will rust, too. Long-term dimensional stability has not been verified to
the same degree as cast iron. Finally, combined welded and cast structures are
becoming popular, now days. They are generally used where a steel structure is
economically suitable but is difficult to manufacture owing to the complexity of
some portions; these complex portions are separately cast and welded to the main
structure.

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

3. Granite: granite is used for surface tables and measuring machine structures. Its
internal damping is better than that of cast iron. Its wear properties are good. It is
reputed to be very stable dimensionally.
Granite has a number of disadvantages. It is becoming more and more scarce. It takes
a long time to cut it out to size, grind and lap it to shape. There are many types of
granite, but most absorb water and the surrounding air humidity affects its
dimensional stability and thus geometrical accuracy.

4. Epoxy concrete: it is a new material specifically developed over the past two
decades for high precision machine tool structure. It is the mixture of binding agent
reaction resin and the hardener together with carefully selected and mixed
aggregates. It is completely new technology as compared with those of the materials
mentioned above. Epoxy concrete offers great design freedom, similar to cast iron. It
has outstanding damping properties better than traditional concrete. It costs
approximately the same as steel reinforced concrete or even less. Epoxy concrete
does not expand and contract with change in humidity, as does ordinary concrete.
Again various material properties can be controlled in epoxy concrete by the type of
mixture chosen. Epoxy concrete has a very high long-term dimensional stability.
Values of some properties and comparison of above discussed material are given in
Table 3.1 and Table 3.2.

Table 3.1 Some properties of some structural material app. Average value [7]
Modulus Coefficient
Specific Thermal Tensile
of Specific of thermal
Material Stiffness conductivity strength
Elasticity Gravity Expansion
N/mm2 0 -1 Wm-1k-1 N/mm2
N/mm2 C

Cast Iron 117000 7.21 16000 12 x 10-6 75 230

Mild steel 207000 7.93 26000 12 x 10-6 80 460
Granite 39000 2.66 15000 8 x 10-6 0.8 14.7
Ep. Con. 33000 2.5 14000 12 x 10-6 0.5 25

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

Table 3.2 Comparison of structure materials [7]

Material Merits Demerits

-Possible to cast it in complex -Comparatively lower strength

and intricate shapes. -Time and cost taken to produce a
C.I. -Easily machined, hand-scraped finished casting
and lapped to high degree of -Technological constraints to produce
accuracy. cast structures i.e. minimum wall
-Fairly good damping properties thickness
-Good anti-friction properties -High shrinkage rates during curing
-Need anti-corrosion treatment
-Very high strength and stiffness -Poor damping compare to cast iron
Steel -Less technological constraints in -Poor frictional properties
weldments manufacturing -Long term dimension stability has
-Structure of steel weldments
not been verified to same degree of
have lower weights, less massive
cast iron
-Need stress relieving
-Need for anti-corrosion treatment
-Damping properties are even -More lead time in cut it to size, grind
Granite better than cast iron and lap it to shape
-Good wear properties -Drilling, machining is difficult as it
-Reputed to be very stable
is very hard
dimensionally
-Used for precision machine tool
Epoxy structures
Concrete -It offers great design freedom
-Outstanding damping properties,

3.4.3 Design Criteria for Machine Tool Structure

Consider a simple machine tool bed with two side walls, which may be
represented as a simply supported beam loaded by concentrated force P acting at its
center, as shown in Fig. 3.1 below:

Fig. 3.1 simply supported beams centrally loaded

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

Maximum normal bending stress acting on the beam is given by the expression:

 
 = (3.1)




Where,  = = maximum bending moment


 = = distance of outermost &ibre from the nuetral axis
2

)*

 = = moment of inertia of the beam section about the neutral axis
12

Upon substituting these values in Eq. 3.1, we get,

+,
3 +,
 = 4 *2 = .
) 2 )
12

If the permissible normal stress under tension for the beam material be denoted by [],
then

3 +,
/0 =
2 ).

*  4
or 12 = ) , = /20
3 6
. 5

where, 12 is the minimum volume of metal required for sufficient strength of beam. For
maximum deflection of simply supported beam, we know,

+, *
7 =
489


where E= Modulus of elasticity of the beam material, If the deflection of the beam is not
to exceed a permissible value, denoted by [], then

+, * +, *
/7 0 = =
489
 )*
489 12

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

.
+ ,.
1: = ) , = ; <
49 /70

where, 1: is the minimum volume of metal required to ensure that deflection of the beam
under load does not exceed the specified value.

The condition of optimum design is:

12 = 1:

.
3 + ,. + ,.
; <= ; <
2 /0 ) 49 /7 0

, . 69 /7 0
= (3.2)
/0

Equation 3.2 indicates that for every structure, there exists an optimum ratio, , . /
depending upon:

a) Operation constraints, expressed in this case through [7],

b) The material of the structure, expressed in this case through E and /0

For example, consider two beams of mild steel and cast iron, with mechanical properties
as under:
For Mild steelE = 2 x 105 N/mm2, [] = 140 N/mm2, [] = 0.002 mm
For Cast Iron E = 1.2 x 105 N/ mm2, [] = 30N/mm2, [] = 0.002 mm

For the steel beam,

,. 6 2 10D 0.002
; < = = 17.14
?@A 140

For the cast iron beam,

,. 6 1.2 10D 0.002

; < = = 48
?@A 30

The volume of the two beams with optimum l/b values will be in the ratio

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

3 + +
48  0.002 (48)
.
1FG 2 3 4 1.2 10
= = = 13.07
1HI 3 + 17.14 +
(17.14) .
2 14 4 2 10 0.002

i.e. If the failure of the beams is determined by the normal stresses under tensile loading,
the volume of the steel beam required to withstand the same load is 13.07 times less than
that of the cast iron beam.

The variation of 12 and 1: for mild steel and cast iron beams with change of
, . / is shown in Fig. 3.2. For identical beam length, the height of the steel section must
be 48/17.14 = 2.80 times greater. Since the volume of the steel beam is 13.07 times less
and height 2.80 times greater than that of the cast iron beam, the thickness of the mild
steel beam will be 36.5 times less.

Fig. 3.2 Variation of V and V with L2/b ratio for cast iron and mild steel

It is evident from Fig. 3.2 that for , . / values less than the optimum
(Corresponding to the point of intersection of V and V curves), the structure should be
designed for consideration of strength, while for , . / values exceeding the optimum
value, the design should be guided by stiffness considerations. In practice, the , . / ratio
for a majority of machine tools lies to the right of the point of intersection i.e. , . / is

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

greater than the optimum value. Consequently, the stiffness and not the load-carrying
capacity of a structure is the decisive factor, which determines its dimensions in most of
the machine tools. So that the steel structure is lighter, deeper and thinner than a cast iron
structure of equivalent strength is obvious. However, since structures are mostly designed
from stiffness considerations, the actual economy of metal consumption by using steel
instead of cast iron may be much less than 13.07 times, because the steel structure must
be provided with stiffening ribs. This not only increases the weight of the steel structure
but also adds to the labor cost [23].

3.4.4 Manufacturing Considerations, Problems and Constraints

Another important factor for deciding the choice of material concerns the
problems of manufacturing that are associated with the use of steel or cast iron structures:

Wall thickness: For a given weight of the structure, high strength and stiffness can be
achieved by using large overall dimensions and small wall thickness. Thus walls of
minimum possible thickness should be employed. Generally, reduction of wall
thickness in cast iron structures is restricted by process capability and depends upon
the size of the casting in case of cast iron. These values are given in Table 3.3.

Size factor N is determined from the relationship,

2K + M + N
J=
4

where, L, B, and H are length, breadth and height of the structure respectively in meters.

The wall thickness may also be determined from the following relationship:

2K + M + N
7 = 10O
3

Internal walls and ribs cool at a slower rate than external walls, and therefore, for them a
minimum thickness equal to 0.8 that of external walls is permitted.

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

Table 3.3 Recommended min. wall thickness for C.I. structures

Thickness of
Size Factor N, Thickness of internal
external walls,
(m) walls and ribs, (mm)
(mm)
0.4 6 5
0.75 8 7
1.0 10 8
1.5 12 10
1.8 14 12
2.0 16 14
2.5 18 16
3.0 20 16
3.5 22 18
4.5 25 20

Welded structures made of steel can have much thinner walls as compared to
cast structures as the technological constraints are much less. Steel structures in which the
wall thickness is less than that of the cast structure by up to 50% are known as thick-
walled structures. They are made of 10-12 mm thick plates and are easy to manufacture,
but they are not particularly effective from point of view of economy of metal.

Walls of different thickness can be welded more easily than cast structure, transition
from one thickness to another (if t1/t2 < 1.5) is accomplished by means of a fillet
radius, of proper value.

Machining allowance for cast structures are generally larger than for weld steel
structures, this is essential to remove the hardened skin of casting and also to account
for casting defects, such as inclusions, scales, drops, etc., that result due to the falling
of sand into the mould cavity.

A welded structure can, if required, be easily repaired and improved. Any corrections
in a cast structure are much more difficult. This property of steel structures is
particularly useful in preparing a prototype.

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

3.4.5 Economic considerations

The final selection of material for structure will in most cases rest upon which of
them provides for a lower cost of the structure. Correct selection can be made only on the
basis of a comprehensive analysis of various factors, some of which are listed below:

Economy of metal: Here it is important to remember that although the weight of the
finished steel structure may be low, the actual metal consumption may be high; this
is due to the fact that whereas holes in castings are obtained with the help of cores,
those in welded structures have to be machined. This results not only in scrap but
also in additional labor cost.
Cost of pattern and welding fixtures.
Cost of machining.

3.5 Basic Design Procedure for Machine Tool Structure

In order to design a particular machine tool structure, it is first essential to draw

up its design diagram. Machine tool structures have, as a rule, highly complicated
profiles. In designing the structure of a machine tool a number of requirements must be
respected. These are the possibility of placing the whole range of work pieces into the
machine, the necessary ranges of travel, sufficient room for chips, room for all
mechanisms and for hydraulic, electric and other equipment, the possibility of easy
assembly of the structure and of its parts and of subsequent dismantling, easy access for
the operator wherever necessary, and the limitation of thermal distortions of the structure.
Further, it is necessary to design all parts of the frame with such shapes and of such
dimensions as to ensure suitable rigidity of the frame.

Forces occur during the machining operation giving rise to deformations, which
disturb the accuracy of machining. Some of the forces do not depend on the intensity of
the cutting process as for instance the weight forces of the moving parts of the machine.
The influence on accuracy of the others, such as cutting forces, is related to the rate of
machining. The relation between forces and deformations and their combined effect on
the machining operation leads to requirements on the stiffness of the individual parts of
the structure and of the structure as a whole.

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

According to various kinds of forces, which occur during the machining

operation, various specifications of requirements on stiffness may be stated. These forces
will be classified into four groups corresponding to four different criteria [23].

1. Deformations caused by weight forces

During the movement of the individual parts of the structure the distribution of their
weights and of the weight of the work piece varies. Consequently the deformations
of the frame vary. The criterion is that any deviations arising do not disturb the
prescribed geometric accuracy of the machine tool.

2. Deformations caused by cutting forces

During the operation the cutting force varies and its point of application moves. In
consequence, the deformations of the frame will vary causing deviations of the form
of the machined surfaces. This effect may be limited by decreasing the cutting
conditions and consequently the output of the operation. Cutting force depends upon
the work piece material; machining parameters, wear of cutting tool etc. For a
designer a knowledge about the nature and direction of the force and the point where
it acts on the structure is often more important than a very precise knowledge of its
magnitude.

3. Forced vibrations
In the machine tool disturbing periodic forces occur. They are caused mainly by the
unbalance of rotating parts and by errors of accuracy in some driving elements. They
excite forced vibrations, which result in the waviness of machined surfaces. The
criterion is to limit forced vibrations so as to achieve to the required surface quality.

4. Self-excited vibrations
Under certain conditions, generally connected with the increase of the machining rate
self-excited vibrations occur and these are energized by the cutting process. They
cause unacceptable waviness of the machined surface and endanger the strength and
life of the parts of the machine and of the tools. The criterion is that in the required
range of operations and of cutting conditions self-excited vibrations shall not occur
and the cutting process must be stable.

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

The individual criteria are almost independent of one another. Nevertheless,

experience shows that criterion 4 prevails and if it is satisfied then criterion 2 and often
also criterion 1 and 3 are more than fulfilled. The problem of stability of the frame
against self-excited vibrations energized by the cutting process is not only the most
important one but also the most difficult. All four criteria determine requirements on
some resulting stiffness, static or dynamic, between the tool and the work piece. By
analyzing this resulting stiffness, requirements on the individual parts of the frame may
be derived.

Members of cutting machine tools are designed mainly on the basis of stiffness
and stability. And thus deflection and deformation of all components along the line of
action of forces should be a minimum. As already stated, machine tool structure can be
broadly divided into three groups. In drawing the design diagrams for structures of each
group the following guidelines may be useful:

Group 1: Structures like beds and columns with fully or partially closed thin box profiles
or consisting of two walls connected by parallel and diagonal stiffeners may be analyzed
as statically indeterminate thin-wall bars.

Group 2: Closed box type structures like housing of speed and feed boxes are designed
for forces perpendicular to the walls, as the latter have sufficient stiffness in their own
plane.

Group 3: Supporting structures like tables knees, etc. which are generally loaded normal
to their base plane analyzed as plates.

Under general conditions of compound loading, most of the machines tools

structures are analyzed as elements subjects to bending in two perpendicular planes and
torsion. It was pointed out earlier also that the basic design requirement of machine tools
is their stiffness. The common design strategy for machine tool structures can therefore
be summed up as:

1. Design for bending stiffness,

2. Designing for torsional stiffness, and

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

3. Checking dimensions for sufficient strength due to bending and torsion.

The design of a structural member is determined by its use. There are three principal
cases:

1. The structural member is to be designed with respect to stiffness for which shape is
the criterion. From the viewpoint of strength the member may then be over
dimensioned. Several members in machine tools fall in this group i.e. bed, column
etc. for those parts which are designed on the basis of stiffness, the dynamic behavior
is of special importance i.e. chatter in cutting machine tools.
2. The structural member is to be designed with respect to strength. Deformations must
remain within allowable limits.
3. The structural member is to be designed with respect to both stiffness and strength.

3.6 Profiles of Machine Tool Structures

During the operation of the machine tool, a majority of its structures are
subjected to compound loading and their resultant deformation consists of torsion,
bending and tension or compression. Under simple tensile or compressive loading, the
strength and stiffness of an element depend only upon the area of cross-section. It is
known from classical mechanics of elastic bodies that in the case of bending and torsion
it is possible to decrease the requirement on material by a suitable choice of the form of
the cross-section, by increasing the second moment of area at constant area of the cross-
section i.e. at constant weight of the element. Another typical feature of machine tools is
the rather small value of the length to width ratio of their parts. Shape and strength are
interrelated and when this fact is disregarded, damage often occurs.

However, the deformation and stresses in elements subjected to torsion and

bending depend additionally, upon the shape of the cross-section. A certain volume of
metal can be distributed in different ways to give different values of inertia and sectional
modulus. The shape that provides the maximum moment of inertia and sectional modulus
will be considered best as it will ensure minimum values of stresses and deformation. The
stiffness of four different commonly used sections of structures is compared with equal
c/s area in Table 3.4.

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

Table 3.4 Comparison of stiffness of different sections having equal c/s area [23]

It is evident from the Table 3.4 that the box-type section has the highest torsional
stiffness and in the overall assessment seems best suited both in terms of strength and
stiffness. The additional advantage that goes in its favor is the ease of proper mating with
other surfaces. Thus, in the case of bending and especially for torsion the optimum from
the point of view of stiffness is that of a closed box cross-section, the bending stiffness of
which is as advantageous as that of the I-section and its torsional stiffness approaches that
of a circular section. All considerations combined point towards the overwhelming
superiority of the box-type profile over others for machine tool structure.

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

In most of the cases the machine tool bed and other structures cannot be in the
form of a closed-box profile. There must be apertures for bearings, openings for free flow
of chips and other purposes. Thus the actual profiles of machine tool structures differ
from a closed-box profile. The apertures and openings in the structure have an adverse
effect upon its strength and stiffness.

3.7 Factors Affecting Stiffness of Machine Tool Structure and

Methods to Improve It
In order to support the work piece and position it correctly with respect to the
cutter under the influence of cutting forces it is necessary for the structure to have high
static and dynamic stiffness values. Stiffness of the structure is related to its shape of
cross-section, cuts and apertures in walls of structures cover plates, arrangement of ribs
internally as well as externally etc.

3.7.1 Effect of aperture on torsional stiffness

In the most of the cases machine tools structures cannot be made of complete
closed box type profile. There must be apertures, openings for free flow of chips and
other purposes. Thus the actual machine tool profile is quite different from closed box
profile. The apertures and openings in the structure have an adverse effect upon its
strength and stiffness. The effect of aperture on the torsional stiffness of a box-type
structure is shown in Fig. 3.3. It can be seen that a circular hole of diameter d affects a
length of approximately twice the diameter, i.e. affected length ,P = 2Q. An elongated
aperture affects the stiffness even more. The reduction in the static and dynamic stiffness
of a structure can be partially compensated by using suitable cover plates. Results using
cover plates are compared in Table 3.5.

It is evident from Table 3.5 that the reduction in the bending stiffness due to apertures
can be compensated to a large extent by using suitable cover plates. However, the effect
on the torsional stiffness is significant and cover plates do not help much in improving it.
For symmetrically placed apertures, the effects can be taken into account by multiplying
the torsional stiffness with a reduction coefficient.

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

Fig. 3.3 Variation of angle of twist as a function of aperture shape and size [23]

Table 3.5 Effect of aperture and cover plate on stiffness of box type structures [23]

3.7.2 Effect of stiffeners (ribs) on stiffness of structure

In a machine tool higher production rate together with good machining accuracy
and surface finish can be achieved by aiming at a structural design that ensures a large
stiffness to weight ratio. Accordingly, lightweight structures possessing large stiffness
can be designed by employing box sections of large overall dimensions and very thin
walls. Only limitation being there load carrying capacity in view of increased danger to

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

warping and buckling. This problem, however, alleviated to a large extent by the use of
suitable ribbing designs. The stiffness of structures can be improved by using ribs and
stiffeners. However, it should be noted that the effect of the ribs and stiffeners depends to
a large extent upon how they are arranged. Sometimes, an increase in rigidity due to
partitions is negligible and does not compensate for the additional consumption of
material and labor required for fabrication. Stiffness/weight ratio is an important factor in
deciding the ribbing arrangements.

3.7.2.1 Effect of End Cover plate on stiffness of structure

Provision of an end cover plate reduces considerably, the deflections in y and z
directions of a thin walled column in torsion Fig. 3.4, while in case of bending no
significant improvement is observed. Thickness of end cover plate is varied and behavior
of structure is observed and after analysis optimum thickness of end cover plate should be
taken. Table 3.6 shows the behavior of column with varying thickness of end cover plate.
It can be observed that thickness of end cover plate equal to the wall thickness is giving
reasonably good result compare to thicker end cover plates [4].

Table 3.6 Effect of end cover thickness on torsional and bending stiffness

Computed deflection (average)

at load point, m
Case
Torsion Bending
Y - comp X - comp Y - comp X - comp
No cover 101.74 122.17 0.177 57.11
End cover
t/2 thick 6.08 14.35 0.116 57.12
t thick 6.38 13.78 0.115 57.12
1.5 t 6.82 13.60 0.115 57.10
2.0 t 6.92 13.50 0.116 57.05
2.5 t 6.97 13.45 0.116 57.02
3.0 t 7.01 13.41 0.117 56.93
3.5 t 7.04 13.38 0.117 56.87
4.0 t 7.06 13.38 0.117 57.80

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

Fig. 3.4 Comparison of cross section deformation with and without end covers plate

3.7.2.2 Effect of ribs arrangement in closed box structure

For the purpose of direct comparison, different ribbing arrangement in case of

closed box-structure is shown in Table 3.7. It is evident from Table 3.7 that only
stiffeners used as shown in arrangements 5 and 6 provide significant improvement in the
bending and torsional stiffness of box-type structures [23]. But the most effective
arrangement of ribs is diamond shaped ribs, which is not shown in above table. The
results of above table can be realized with graphical plots, Fig. 3.5 (a) and (b) [4].

Fig. 3.5 (a) Stiffness variation with different ribbing arrangement with and without end
covers (b) Stiffness variation as a function of different ribbing arrangement

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

Table 3.7 Effect of stiffener on bending and torsional stiffness of box-type structures

3.7.2.3 Effect of Vertical Stiffeners

Fig. 3.6 shows the columns having internal and external vertical stiffeners,
which have been analyzed. Each side of stiffener cross section is kept equal to wall-
thickness of the column. In both cases, vertical internal and external stiffeners, depth of
the stiffeners, denoted by a, is varied in order to analyze effect on performance.

Fig. 3.6 Columns with vertical internal and external stiffeners

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

Table 3.8 Effect of external and internal vertical stiffeners

Bending Torsion
Structure amm Per cent Per cent Stiff/Wt. Per cent Stiff/Wt.
weight rigidity ratio rigidity ratio
ST -BI.1 ----- 101.24 138.0 1.363 182.0 1.798
ST -BI.2 ----- 101.24 132.0 1.304 178.0 1.761
ST -BI.3.1 4 102.60 155.1 1.512 219.8 2.142
ST -BI.3.2 6 104.24 170.1 1.632 235.3 2.257
ST -BI.3.3 8 105.65 183.6 1.738 249.3 2.360
ST -BI.4 ----- 102.60 141.1 1.375 176.2 1.719
ST -BI.5 ----- 105.65 179.9 1.703 254.7 2.411
ST -BE.1 ----- 101.24 138.3 1.366 179.9 1.777
ST -BE.2 ----- 101.24 133.0 1.314 174.0 1.719
ST -BE.3.1 4 102.60 155.6 1.520 212.7 2.073
ST -BE.3.2 6 104.24 171.4 1.644 227.4 2.182
ST -BE.3.3 8 105.65 185.0 1.751 234.0 2.271

It can be observed from Table 3.8 that for similar arrangements the external vertical
stiffeners are more effective in bending loads while internal vertical stiffeners are more
effective in torsional loads though the difference is very small.

3.7.2.4 Effect of Horizontal stiffeners

Fig. 3.8 shows the positions of internal and external horizontal stiffeners. Depth
a of stiffeners is varied in steps as shown in Table 3.9, which also shows results of
combination of horizontal and vertical stiffeners, to analyze its effect on performance of
structure. Large improvement in torsional rigidity by these stiffeners is due to their
resistance to rotation of the column. But under bending loads these stiffeners are less
effective. Columns having internal horizontal stiffeners are stiffer than those having
external horizontal stiffeners. As earlier said, these stiffeners have very high torsional
rigidity, while under bending loads they are less effective.

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Fig. 3.7 Columns with horizontal stiffeners

Table 3.9
.9 Effect of Combination of both horizontal
ontal and vertical stiffeners

Bending Torsion
Structure amm Per cent Per cent Stiff/Wt. Per cent Stiff/Wt.
weight rigidity rigidity ratio ratio
ST - CI.1 4 103.30 143.2 1.387 279.3 2.704
ST- CI.2 6 104.88 148.2 1.413 316.8 3.020
ST - CI.3 8 106.42 156.3 1.469 350.2 3.291
ST - CE.1 4 103.66 139.9 1.349 274.1 2.644
ST - CE.2 6 105.56 148.2 1.404 307.1 2.910
ST - CE.3 8 107.50 155.4 1.445 337.0 3.135
ST - DI.1 ----- 106.01 175.8 1.659 336.2 3.172
ST - DI.2 ----- 108.80 201.2 1.849 373.8 3.436
ST - DE.1 ----- 106.40 177.3 1.667 322.4 3.030

Generally, combination of both horizontal and vertical stiffeners is provided in

column to improve stiffness of the column in both bending and torsional loading.
Columns ST-BI.3.1
BI.3.1 and ST-BI.5
ST having verticall stiffeners, as shown in Fig. 33.6, are
combined with the column ST
ST-CI.1
CI.1 having horizontal stiffeners to get the stiffener
arrangements with ST--DI.1 and ST-DI.2 respectively, in Table 3.8,
.8, while in arrangement
ST-DE.1,
DE.1, the stiffeners of columns ST-BE.3.1
ST E.3.1 and ST.CE.1 are combined.
combi It can be seen
from Table 3.8
.8 that ST
ST-DI.2
DI.2 has the highest stiffness/weight ratio for both
bot bending and
torsional loading [5].

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

3.7.2.5 Effect of Fastening bolts and External Vertical stiffeners at bottom

The stiffness of structures can also be improved by providing a proper
arrangement of fastening bolts. The effect of bolt arrangement and stiffening ribs on the
bending and torsional stiffness of a vertical column is depicted in Fig. 3.8. It is evident
from the Fig. 3.8 that by arranging the fastening bolts uniformly the stiffness can be
improved by 10-20%.
20%. By additionally providing flange stiffeners, at bottom, the column
stiffness can be increased by almost 50%. Rigidity of the machine tool as a whole
depends
ends upon the rigidity with which various units are clamped. It should be kept in mind
those joints between various structural elements e.g. joints between the head stock and
tail stock to a lathe with bed, the base plate of a drilling machine with its column
col etc.
should
ld be made as rigid as possible [23].

Fig. 3.8 Effect of bolt arrangement and

and external bottom stiffeners

Fig. 3.9 shows the columns having different arrangements of flange type
stiffeners, which have been analyzed. These columns have higher stiffness because these
types of stiffeners have the effect of reducing the effective length of the column thereby
reducing the deflections. For the present case the effective length of column is reduced by
150 from total height of 500 mm. ST
ST-A.M
A.M is the column, which is assumed to be
clamped at a distance of 150 mm (height of the stiffeners) from the bottom. This column

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

will have the highest possible stiffness that can be achieved by this type of stiffening
arrangement.

Table 3.10 shows the effectiveness of different ribs positions in bending and
torsional loadings. Base width of stiffeners is then varied, the parameter shown by a in
Fig. 3.9, keeping the thickness of the stiffeners equal to wall thickness of column in all
cases.
Table 3.10 Effects of External Vertical Bottom Stiffeners

Bending Torsion
Structure amm Per cent Per cent Stiff/Wt. Per cent Stiff/Wt.
weight rigidity ratio rigidity ratio
ST - UR ----- 100.0 100.0 1.000 100.0 1.000
ST-A.M. ----- ----- 247.0 ----- 223.8 -----
ST - A.1 60 103.8 124.8 1.203 146.0 1.408
ST - A.2 60 103.8 124.6 1.200 150.1 1.449
ST - A.3 60 108.6 132.6 1.221 153.9 1.416
ST - A.4.1 20 107.6 115.4 1.073 131.9 1.226
ST - A.4.2 40 111.4 185.9 1.669 171.1 1.536
ST - A.4.3 60 115.5 189.8 1.643 176.2 1.526
ST - A.4.4 80 119.4 193.1 1.617 177.2 1.484

Fig. 3.9 External vertical bottom stiffeners

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

From the Table 3.10, it can be seen that for stiffening arrangement ST-A.4, a =
40, has highest stiffness in bending. This is because this stiffening arrangement reduces
the distortion of column wall. Increasing the base width of the stiffeners increase the
rigidity but increasing it beyond a certain limit is less effective as indicated by falling
stiffness to weight ratio, shown in Fig. 3.10, below. The corner stiffeners of ST-A.5
becomes less effective under bending loads, but under torsional load all the stiffeners are
effective in reducing the column rotation thereby increasing the rigidity of column[5].

Fig. 3.10 Effect of stiffener base width on stiffness/weight ratio and rigidity

3.7.2.6 Improving Stiffness of Open Structures

The stiffness of open structures, such as lathe beds where two plates of
structures, top and bottom, connected by ribs, also get affected by arrangement of ribs.
The torsional rigidity of open structures has been compared under different stiffener
arrangements and the results are shown in Table 3.11, below. The results of table indicate
that only arrangements 4 and 5 are effective in terms of stiffness-to-weight ratio of the
structure. Arrangements 4 consisting of two parallel shears, which are connected by
diagonal ribs, is commonly used in machine tool beds.

Finally, stiffness to weight ratio is important factor in deciding the ribbing

arrangements. Higher values of stiffness to weight ratio is desirable. Because ribs
increase stiffness of structure but it also increase weight on other hand. So to arrive at
final arrangement of ribs, one has to see value of stiffness to weight ratio. Again
increasing no. of ribs means adding material and so adding cost, finally. Apart from

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

economical reasons, a high stiffness to weight ratio will increase the values of natural
frequencies of the structure, which may then become free of any resonant vibrations in
the operating range thus improving dynamic conditions [23].

Table 3.11 Effect of stiffener arrangement on torsional stiffeners of open structures

3.7.3 The significance of joints and their orientation upon the overall stiffness of
structure

It is well established that one of the great obstacles to a complete understanding

of the static and dynamic behavior of machine tool structure is the inability to take the
effects of the joints fully into account. Contribution of various parts of structure in overall
flexibility of machine tool, and actual machine tool behavior, as a whole, differs. This is
because during analysis of individual structural elements, joint properties of machine tool
are not specified; however, it is of much importance. Because resultant force will transfer
from one part to another through contact area, which is nothing but a joint, either fixed
or sliding.

In design of machine tool structure, designer is often faced with a decision as to

on which plane the joint should be provided between two elements. Again joints are
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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

present as an essential part of the functional requirements in the operational movements,

and also enable the manufacture and machining of the elements. In large machine tools,
joints are also required to assist in the transportation of the finished machine.

Joints in machine tools may be of two basic forms, depending upon the relative
movement, which takes place between the joint interfaces:

1. Joints, which connect structural parts without any intended motion, e.g., the joints
between the headstock and bed of a lathe, these are called fixed joints
2. Joints, which connect parts, which are to have intended relative motion to one
another, e.g. joints between the saddle and bed of a lathe, these are called sliding
joints.

It is sometimes necessary for elements to be jointed together and possess both the
qualities of fixed and sliding joints, as in the case of the joint between the tailstock and
bed of the lathe.

As the joints form a link or a number of links in the chain of elements closing the flow of
the cutting forces, they should possess a stiffness matching that of the other structural
elements; even having other structural elements of a high stiffness would not help if there
were only one flexible joint in the chain of elements, i.e. springs in series.

Following properties of joints require attention:

a) The static and dynamic stiffness of joint faces loaded in a plane normal to the joint
surface;
b) The significance of joints on the overall deflection of the structure
c) The damping effect of joints

Research into the overall stiffness of structure has shown that the joints usually
incorporate a high percentage of the overall deflection. According to some results,
deflection due to joints is of the order of 85 to 90% of the total structural static deflection
in a machine tool.

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

Investigations to study the dynamic characteristics of joints have shown that damping
may be obtained in a joint but only at the expense of stiffness. From the metal removal
viewpoint, damping in a machine tool is advantageous. Joints do introduce frictional
damping which is greater in value than internal material damping. The relative
displacement between sliding elements have to be limited especially when they are
situated in series with other elements. In this case, an increase of frictional damping
within joints, at the expense of decreasing their static stiffness, is hardly justified.

With regards to above facts, the most efficient method to achieve both stiffness and
damping would be to design the joints for maximum stiffness and to introduce damping
by external means such as vibration absorbers.

3.8 Evaluation of Machine Tool Structure

The analysis of static rigidity and dynamic characteristics of machine tool
structures is one of the most important factors in designing high-precision and high-
efficiency machines. In present work, an attempt is made to explore the meaning of
analysis, both static and dynamic.

In order to evaluate operational efficiency and accuracy of machine tools at the

design stage, and finally to optimize the machine structures with respect to the
performance, structural analysis using computer programming/software must be
conducted. The extent to which the behavior of the various elements of the machine
contributes to its overall performance is by no means fully understood. However, the
results of research together with the experience of the user form the basis for the design
procedures currently available. The aim of this chapter is to present systematic
procedures for the analysis of the machine tool structure a prerequisite of the sound
systematic design. It is useful to know how the actual design will work in actual
condition.

To achieve perfection in machine tool structure design, one has to check the
design alternates for both the conditions, i.e. statically, which considers only time
independent parameters, and dynamically, which takes care of dynamic behavior of
structure, during actual machining. So in short, we arrive at,

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

a) Static analysis, and

b) Dynamic analysis of machine tool structure.

3.8.1 Static Analysis

Forces of an essentially static nature result from the static component of the
cutting force, the weight of the various machine elements and thermal stresses. The latter
source of stressing is not considered here although the methods to be discussed are
adaptable to the thermal problem.

Thus the static problem is defined as that of obtaining a measure of the deformed
shape of the structure under the action of both the cutting force and the distributed gravity
force. Although the changing distribution of the gravity force, due to the movement of the
machine carriages and the variable magnitude and direction of the cutting force add to the
complexity of the problem this is by far outweighed by simplifications arising from the
linear behavior of the stressed structure.

If only the static deformation of the structure is of interest it is generally

adequate to obtain a measure of the three orthogonal displacements of each selected node.
Whilst a knowledge of the relations of the nodes would lead to a more accurate
construction of the deformed shape this is usually unnecessary. However, the formulation
of the static characteristics represents the first requirement of more general dynamic
analysis and where this is required the inclusion of node rotations will lead to a more
accurate assessment of the frequencies and modes of natural vibrations. This is especially
critical for the higher modes involving significant rotations of the elements. [3]

3.8.2 Dynamic Analysis

The dynamic analysis was carried out to determine the natural frequencies, the
mode shapes and resistance to chatter. The dynamic behavior of the machine may be
expressed in terms of its deformation resulting from the action of harmonic forces. These
forces arise from two basically different sources. Firstly there exist the externally applied
dynamic forces resulting from the intermittent nature of certain cutting processes and
unbalanced rotating motors, shafts, gears, etc. secondly, self-induced forces are created

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

by the dynamic motions of the structure itself. [3]

These forces include:

a) A force dependent upon the dynamic variation in the cutting condition of the tool
relative to the work. ( e.g. chip thickness variation)
b) The inertial force distributed throughout the entire structure caused by its
acceleration during dynamic motion.
c) A distributed damping force.

The damping capacity of a machine tool is an important feature of its dynamic

performance and any model which excludes damping is of only limited value. It is not
possible at present to define the distribution of the damping force, prior to manufacture,
with sufficient accuracy for it to be of practical value.

Still it is not easier every time to predict the dynamic characteristics at design stage. The
following problems exist for evaluating characteristics of machine tool structures at
design stage:

1. A machine tool structure has an infinite degree of freedom in dynamics. Therefore,

an infinite number of natural modes exist in a machine structure. How to efficiently
select natural modes necessary for evaluation of the characteristics among an infinite
number of natural modes is very important, but in many cases thorough
consideration is not given to this problem. When commercially available structural
analysis programs of the finite element method, such as Pro/Mechanica, NASTRAN
etc. are used, large amounts of information at many natural modes are output. In
some cases, it is difficult to judge whether or not information at computed natural
modes is sufficient to evaluate the characteristics.

2. At the design stage, evaluative parameters having errors which are difficult to
exclude must be distinguished from parameters which can be obtained with sufficient
accuracy. In vibrational characteristics of machine structures, accurate values of
damping ratios denoting damping capacity are difficult to obtain at the design stage.

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

In such a case, damping ratios must be analyzed based on the consideration of the
existence of errors.

3. Often in practical machine tool structures, directional orientations of the excited

force change greatly, or the waveform of the excited force in time domain is
unknown. For example, in machine tools, the directional orientations of the cutting
force, etc. may change greatly as a result of the machining conditions and operational
states. The evaluative method must be able to cope with such practical situations.

One of the most broadly applicable approaches to computer-aided machine

dynamic analysis and design is use of a maximal set of Cartesian generalized coordinates
to locate and orient bodies in space. Connections or constraints between bodies are then
imposed to represent kinematics of the system. Constraints include kinematics relations
that describe interconnections and driving constraints that describe specified inputs to the
system. The resulting equations of motion of constrained multi body dynamic systems
comprise a mixed system of differential and algebraic equations (DAE). Constraint
stabilization method is used to solve set of DAE.

3.8.3 Relation between Static and Dynamic Analysis

It will be explained that if between two particular points of the structure with
particular directions (P) of the force and (x) of the displacement, at one time the static
stiffness and at other times the dynamic stiffness are considered, the significance of the
static stiffness of individual element is different for each of both stiffness. Moreover, the
dynamic stiffness being a function of frequency the significance of the static stiffness of
the individual elements of the structure for the resulting stiffness must vary with the
frequency.

Nevertheless, especially if the resulting stiffness as previously defined between

tool and work piece, k and k, are concerned, experience shows that from the dynamic
point of view the basic modes of natural vibrations are more important then the higher
modes. It is mainly in the higher modes that the significant springs are very different
from the significant springs resulting from the static considerations. In the basic modal
shapes the roll of the individual springs would be approximately the same as in the static

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

deformation shape, if the damping was regularly distributed in the frame.

Therefore, it may be concluded that if the stiffness of those springs which contribute
mostly to the static resulting stiffness, K or K, respectively, are increased then the
dynamic stiffness corresponding in point of action and directions of the force with K or
K, respectively, will also increase. It may be that some of the springs which are
significant statically are non-important dynamically because of a high damping in the
corresponding part of the frame, so that their stiffening from the dynamic point of view is
unnecessary and some effort would be wasted if as basis for the improvement of the
structure the static instead of the dynamic analysis were used.

3.9 Analysis of Machine Tool Structure

In earlier times, when other efficient methods of analysis were not explored and
used, some other techniques were used. Analysis of the prototype was done by preparing
one scale down model of the prototype and the performance of the machine tool was
approximated. It is known as Model analysis. The method is discussed in some details:

3.9.1 Use of Models for Analysis of Machine Tool Structures

Reduced scale models are the most direct form of analog and since they had
proved valuable in other fields, it seemed reasonable to try it for machine tool structures.
Although the overall cutter-work piece flexibility is the property required for the
prediction of machine tool performance it is evident that a geometrically similar model
can only predict this property correctly if the detail behavior of the model is also similar.
For this reason the investigation has involved a very detailed examination of a complete
prototype machine tool and a model [1].

Basic Considerations and Preliminary experiments:

1) Choice of Model Material:

Reduced scale models were decided to make of thermoplastic for two reasons:
a) It was hoped that thermoplastic models would be easy to construct and alter as
required.
b) The mechanical properties of thermoplastics are related to those of cast iron,

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

and that of steel in such a way that the resonant frequencies of models would
come comfortably inside the bandwidth of readily available test equipment.
Perspex was chosen from among the various possible thermoplastics because:
1) It was readily available in suitable forms
2) Methods of fabricating it are highly developed
3) Information was available about its mechanical properties, especially
dynamic.
2) Tests on simple beam Models:
Experimental work started with vibration tests on calculable beam models whose
important behavior was found to be as predicted within the limits of experimental
error. The technique of using inductive proximity pick-ups for displacement
measurement was evolved at this stage.

3) Tests on an actual Machine Tool Structural Element and a Model thereof:

The next step taken was to test the validity of a model of a complex beam like
structure by comparing it with a prototype.

In an experiment, a scale Perspex model and cast iron prototype was very good
both in respect of resonant frequency and mode shape.

The results obtained with testing models separately differ from the behavior of
complete machine tool. From this it became clear that the only really useful sort
of model would be a complete one in which the detail load distributions on
individual elements would be automatically similar provided that the model was
truly similar to the prototype. Unfortunately a difficulty arises when trying to
make a scale model of a complete machine tool. The reason for this is that almost
no information is available about the mechanical properties of joints in machine
tool. Hence it was decided to try to solve the basic problem of predicting overall
flexibility with model in two stages:

a) Use a model to represent the metallic structures only in the fist instance and
keep the effects of the joints to a minimum by eliminating sliding clearances.
b) Introduce the effect of the joints later by some means

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

Although, the analysis using scale models give faithful results, the major drawback
of the technique is inability to check design alterations for finding the optimum
design. Again the technique requires ample time to construct very similar model of
prototype with required accuracy.

3.9.2 Mathematical Model approach for Analysis of structures

The limitations of physical model techniques, in other branches of engineering

led to the development of mathematical models representing a variety of mechanical
structures. The development of the analytical approach has accelerated rapidly since the
introduction of large digital and analogue computer installations, especially in the
structural and aircraft industries and numerous examples of the computer analysis of
many structures are now to be found in the technical journals of these industries.

In developing a mathematical model careful consideration must be given to the

problem as a whole. Firstly the information required from the solution of the model must
be defined and secondly the availability of the fundamental information required by the
model should be considered both quantitatively and qualitatively. A detailed discussion
of all the available method is beyond the scope of this chapter.

Firstly, the machine tool structure is considered too complicated geometrically

to use classical formulations involving the expression of elasticity and mass as
continuous functions of the structural dimensions and subsequently calling for the
solution of partial differential equations. Hence, the method adopted will be based upon a
lumped representation of the elasticity and mass. Thus the structure is approximated to
by a model composed of a number of interconnected weightless springs (beams) and
concentrated masses. A simple portal frame and its lumped parameter model are shown in
Fig. 3.11 below [2].

Fig. 3.11 Lumped model of portal frame

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

The dynamic behavior of such a model may now be obtained from the solution
of the set of ordinary differential equations yielding a number of natural frequencies and
corresponding normal mode shapes. The latter will be defined by the amplitudes of
displacements of all the mass points during the vibration of the structure at a natural
frequency. If the structure is sufficiently simple it is possible to estimate some of its
modal shapes and so use this information to calculate the potential and kinetic energies
and hence deduce the natural frequency corresponding to the assumed mode shape. This
approach might be applicable to the calculation of some of the lower natural frequencies
of certain machines but it is of very limited practical value.

Fortunately the solution of the equations describing the behavior of the

lumped model presents no difficulty if a sufficiently large computer is available.
Available computer routines require the formulation of problems of this type in matrix
notation. The systematic character of matrix methods also permits large amounts of
information to be handled by routine procedures.

3.9.3 The Lumped Constant Model

By far the most important step in the lumped constants method is that of
transforming the actual structure into a representative lumped model. This is by no means
a straight forward task and attention must be given to a number of considerations.

Firstly the structure should be replaced by a line diagram describing its overall
topology. Thus each section of the machine is represented by a single line drawn through
its principal elastic axis and the whole structure is composed of the interconnection of
such lines. Typical examples are shown in Fig. 3.12, next page. Next consideration
concerns the number of further subdivisions and their locations. This will be dictated by
the following four factors:

a) Since the analysis will yield the deflections at discrete points resulting from static or
dynamic deformation, these points (nodes) should be sufficient in number and of
such a distribution to enable a practically useful deformation shape to be determined.
b) Where, two elements are physically joined, or where a change in the cross section of
an element or the directional orientation of its principal elastic axis occurs, at least

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

one additional node is required. In the case of a clamped or bolted joint it is desirable
to place a node at either side so that the joint stiffness characteristics, if known, can
be included with ease.
c) For the subsequent dynamic analysis the number of nodes must be sufficient to
represent reasonably the actual mass distribution when this is replaced by
concentrated masses at these nodes.
d) From the computational point of view the minimum number of nodes consistent with
the latter requirements should be selected.

Fig. 3.12 Lumped models of a) Radial Arm Drill

b) Center lathe

c) Horizontal milling machine

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

It is not possible to give a rigid set of rules which will satisfy all of these
requirements and to some extent experienced judgment must be used. If only the static
deformation of the structure is of interest it is adequate to obtain a measure of the three
orthogonal displacements of each selected node. Whilst a knowledge of the rotations of
the nodes would lead to a more accurate construction of the deformed shape this is
usually unnecessary. However, the formulation of the static characteristics represents the
first requirement of the more general dynamic analysis and where this is required the
inclusion of node rotations will lead to a more accurate assessment of the frequencies and
modes of natural vibrations. This is especially critical for the higher modes involving
significant rotations of the elements. Therefore, the static analyses to be carried out will
account for the application of forces and moments at all the selected nodes and the
resulting rectilinear deflections and rotations of such points.

3.9.4 FEA: An Efficient, Quick and Reliable Technique of Analysis

As explained, the earliest accepted method of analysis prior to manufacture of
the actual machine is model analysis. This method involves manufacture of a scale model
of proposed design. Since, such a model is reasonably faithful representation of the actual
design, a considerable amount of useful information is obtained from subsequent testing.
However, with this method it is not possible to check different design variations in
structure, because it requires every time modified model to be prepared. Thus, physical
prototyping is an expensive, time-consuming way to do this, and the usual alternative
traditional numerical analysis depends on highly trained specialists to get accurate
results.

The limitations of physical model techniques have led to the development of

mathematical models representing a variety of mechanical structures. In all the
mathematical models, the first step is to subdivide the real structure into simple elements
such as beams and polygonal plates, these elements being interconnected at specified
nodal or station points only. Then relationships between the forces and displacements at
these nodal points are then derived in the form of element matrices, the manipulation of
these element matrices giving the required information about the whole structure. As in
this approach, whole structure is divided into finite elements, it is known as Finite

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CHAPTER 3 DESIGN OF MACHINE TOOL STRUCTURE AND ANALYSIS

Element Analysis. The FEA is a very useful tool in engineering today and same has
proved to be an important technique in machine tool structural analysis. Furthermore,
FEA can also be used to determine portions of an object which are more massive than
required, and therefore can be reduced in amount of material. This can be a useful tool in
streamlining and perfecting a product where weight, size, or material is of critical
concern.

Delivering higher quality products with tighter schedules compels companies to

adopt computer aided engineering (CAE) software as an intrinsic part of their design
process, i.e. Creo 1.0, I-Deas, ANSYS, Nastran etc., which are quicker, reliable and
efficient in performing even more complex and odd cases of real world problems. Thus,
Computer is an invaluable tool for a designer in his task for evaluating alternative designs
to arrive at the optimum design and also predicting the static, dynamic and thermal
behavior of the machine before arriving at the final design.

In next chapter, after studying design aspects of machine tool structures, analysis
of a Turning centre is done for its major structural parts, i.e. Head, Saddle and Bed and
then according to the results design optimization is suggested where required. For
analysis of such a complex structures Pro-Mechanica, simulation module of Creo 1.0, is
preferred over other simulation software.

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