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DOI 10.1007/s10999-007-9033-3
Received: 22 September 2006 / Accepted: 11 June 2007 / Published online: 23 January 2008
Springer Science+Business Media B.V. 2008
J. D. Suh
Fuel Cell Vehicle Team1, Advanced Technology Center,
Hyundai Motor Company, 104, Mabuk-Dong,
Giheung-Gu, Yongin-Si, Gyeonggi-Do 446-912,
Republic of Korea
D. G. Lee (&)
Department of Mechanical Engineering,
Korea Advanced Institute of Science and Technology,
ME3261, Guseong-dong, Yuseong-gu,
Daejeon-shi 305-701, Republic of Korea
e-mail: dglee@kaist.ac.kr
1 Introduction
Modern precision machine tools are required to
produce precise products at high machining speeds.
To achieve the requirement, machine tools must have
high damping as well as high structural stiffness.
Modern machine tools are usually equipped with high
speed spindle systems rotating up to 35,000 rpm and
moving frames operating up to 30 m/s2 acceleration
and deceleration (Suh and Lee 2002). At these high
operation speeds, machine tool structures are vulnerable to vibration, which results in poor surface finish
and inaccurate dimensions of products (Suh and Lee
2004). Besides, chatter, a kind of self-induced
vibration, adversely affects tool life (Clancy and
Shin 2002). The vibration of a machine tool is
frequently caused by the low damping: if the
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J. D. Suh, D. G. Lee
Sand Polyester
30.3
15.4
7.1
7.1
30.0
10.0
Vol.% 26.7
13.6
6.3
6.3
26.4
21.8
115
0.10
Polyester
Granite
0.06
Damping factor
Damping factor
0.08
0.04
0.06
0.04
0.02
0.02
0.00
0.00
100
50
100
150
200
Frequency [Hz]
250
300
PC
String
Specimen
Impact hammer
FFT Analyzer
Accelerometer
Amp
Polymer concrete
0.08
Steel
1000
Frequency [Hz]
10000
Amp
Length (mm)
Height (mm)
Width (mm)
240
97
97
360
97
97
480
97
97
E (GPa)
G (GPa)
2260
25.2
10.5
0.2
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J. D. Suh, D. G. Lee
25
20
15
10
5
0
0.40
0.60
0.80
1.00
Ra [m]
1.20
1.40
1
FR2
DP2
x X
Additional advantage of the sandwich structure is that
the steel faces not only increase structural stiffness
but also work as a mold for polymer concrete during
manufacturing.
Figure 6 shows the high-speed gantry-type milling
machine tool structure investigated in this work,
whose specifications are shown in Table 4. The
machine tool bed is a hybrid structure composed of
welded steel base in Fig. 7 and polymer concrete core
filled its inside cavity. The machine tool bed of this
type has two functions, i.e., the linear motor
123
Value
Size (X 9 Y 9 Z, mm)
0.9 0.3
30
21
35,000
117
B. C.
Source
Fixed
Linear motor
15.1 kN
Inertia force Fy
LM-guide
21 kN
7.6 kN
Pulling force Fp
Inertia force Fx
-5.7 kN
Inertia force Fz
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J. D. Suh, D. G. Lee
Linear motor
LM-guide
Max dm
Min dm
D dm
Max dg
Min dg
D dg
48.8
6.5
42.3
14.5
6.5
8.0
51.2
6.5
44.7
15.0
6.5
8.5
55.6
6.5
49.1
15.5
6.6
8.9
48.8
6.8
42.0
14.5
6.8
7.7
51.5
6.8
44.7
15.0
6.8
8.2
55.7
6.9
48.8
15.5
6.9
8.6
20 20 20 10 10 10 10 10 10 10 50 20
15 20 15 10 10 10 10 10 10 10 50 20
10 20 10 10 10 10 10 10 10 10 50 20
20 20 20 10
5 10 10 50 20
15 20 15 10
5 10 10 50 20
10 20 10 10
5 10 10 50 20
123
119
1st
2nd
3rd
4th
104
108
185
203
103
107
179
199
3
4
99
104
104
106
172
185
191
203
102
105
179
198
99
102
172
190
424
P2
128
tC
X1
X3
X2
U US UC
2 !
ZZ 2
rz;S
rzx;S
dz dx
2ES
2GS
AS
2
2 !
ZZ
rz;C
rzx;C
dz dx
2EC
2GC
Amplitude of
the 1st mode shape
0.8
Static deflection
0.6
0.4
0.2
0.0
0.2
0.4
0.6
0.8
Normalized position [Z / Z max]
rzx;S
rz;C
EC M x
D
Fig. 11 Comparison between the 1st vibration mode amplitude and static deflection of the vertical column by
concentrated loads in Fig. 10
V
Rx
0
EC X dX
D
AC
1.0
rxz;C
283
P1
674
Steel
Polymer concrete
ES M x
D
Rx
R T
V EC 0 C X dX V ES TC X dX
D
D
rz;S
WD
WD;S WD;C
g US gC UC
S
US UC
2pU 2pUS UC
7
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120
J. D. Suh, D. G. Lee
0.025
FR F
0.020
0.015
0.010
0.005
0.000
50
123
100
150
Frequency [Hz]
200
250
121
93
4.13
130
3.15
155
5.69
200
2.93
f2 f1
fr
5 Conclusion
In this study, a polymer concrete bed combined with
welded steel structure, i.e. a hybrid structure, was
designed and manufactured for a high-speed gantrytype milling machine. The optimal mixing ratio of
aggregates for polymer concrete considering packing
was obtained experimentally. Then the mechanical
properties of polymer concrete as well as adhesion
properties to steel adherand with respect to its surface
roughness were measured. The dynamic characteristics of the hybrid polymer concrete bed were
measured by impulse dynamic test. From the impact
dynamic test, it was found that the hybrid machine
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