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3 1 PDF
1 SUPPORTING STRUCTURE OF
MACHINE TOOLS
Twelve following subsections will discuss the essential assembly groups of CNC very complicated optimization processes
machine tools which are common for all types. Theoretical bases and principles leading to improvement and increase of
which are used and quoted here to the great extent are borrowed from [Borský 1991], machine parameters. In many cases the
[Borský 1992a], [Borský 1992b] and from company literature. Moreover, author’s application of these advanced optimization
knowledge especially in the field of servo drive dimensioning is applied here. methods requires not only great demands
Requirements put
on the supporting structure
While designing a supporting structure, the
designer must respect many points of view
which can be summarized in some essential
and generally valid requirements as the
following ones are:
• application of the top-quality material
for the frame;
• good static rigidity;
• sufficient dynamic and temperature CARRYING SYSTEM
stability;
• to enable good chip removal; MOVABLE IMMOVABLE
WORKPIECE CARRYING
Carbon fibre HM
Carbon fibre HT
Carbon fibre HT
Aramid fibre
stiffening ||
stiffening ||
stiffening ||
stiffening ||
stiffening #
stiffening #
Polymere
Steel Cast iron HPC concrete
concrete
Specific weight [kg.m –3] 7 850 7 200 2 300–2 500 2 200–2 500 1 600 1 600 1 600 1 600 1 400 2 000
Tensile strength [MPa] 400–1 600 150–400 10–40 8–10 1 200 400 2 400 800 200 1 100
Coefficient of linear expansion [10 –6/K] 11–18 10 9–18 10,6 –0,5 –1 0 0,5 –3,5 5
Specific heat capacity [KJkg –1 K –1] 0,49 0,45 0,7–1,3 0,9 1 1 1 1 1,5 1,1
Tab.3.1.1: Physical properties of materials for supporting structures [Mráz, Talácko 2006]
on developers but it also requires costs on • low internal stress among the particular components. From
commercial calculation systems enabling (long-term accuracy); this point of view, the following materials
to perform optimization. Another problem is • low thermal dilatability are important ones: fibre or particle com-
unfamiliarity with linkages or spare calculation (thermal stability); posites, materials containing foamy filling
models describing behaviour of the real • low energetic costs for material or macroscopic combinations of these
supporting structure accurately enough. acquisition; materials with conventional materials
Due to this, the conservative solution is often • low material costs. based on Fe-C designated as hybrid
selected to avoid unexpected complications structures.
and uncertainties, not the optimum solution As it can be seen from the above-mentioned Tab. 3.1.1 summarizes the essential phys-
or the solution which is very close to the facts, the requirements are often con- ical properties of materials for supporting
optimum one. tradictory ones. The mechanism of the phys- structures.
ical damping principle is very complicated The most common material used for
Material and it is still the subject of research. From supporting structures are metallic materials
It is possible to use various materials for the technical point of view, it is possible to (ferro-alloys) (Fig. 3.1.3).
the design of the machine-tool supporting state that high values of internal damping The principles given in Fig. 3.1.4 [Janda,
structure, grey cast iron, steel and cast steel can be found especially at materials Divišová 1990] are valid for designing of
are most often used, but lately also various composed of more macroscopic phases or castings, especially for continuity of ribs
nonferrous materials, especially concrete at materials with many internal interfaces and countersurfaces.
and polymere concrete have been used to
a still greater extent (Fig. 3.1.2). Ferro-alloys for castings
While selecting the material kind, it is
always necessary to assess especially the
essential physical properties of the particular
material which directly influence the specific Cast iron types Steel types for castings
technical and operation machine properties • spheroidal graphite ferritic cast iron, spheroidal • carbon steel for castings
graphite ferritic perlitic cast iron (422602 = GS 38)
(Fig. 3.1.2). The material must have these (422303 ≡ GGG 35) • ferritic-perlitic steel for castings
important properties: • flake graphite perlitic grey cast iron, (422643 = GS – C25)
• high rigidity and strength flake graphite ferritic grey cast iron • manganese steel
(422415 = GG 15) (422660 = GS 60)
(safety against permanent deformation • malleable cast iron • silicon steel
and breakage); 422532 (422819 = GRADE 3A)
• chrome-manganese vanadium steel
• low weight (422830 = GS 50)
(static and dynamic properties);
• high damping of vibrations etc.
(dynamic properties); Fig. 3.1.3: Ferro alloys used for building of supporting structures
(3.1.1) Offset
b 6 10 10 12 15 18 20 25
where l, b, h are the length, the width [mm]
and the height of the cast part. The wall
Fig. 3.1.6: Dimensions of welds [Janda, Divišová 1990]
thickness is assigned to this number (see
Fig. 3.1.5). The casting shape shall be as
simple as possible and after the design • cast iron has a smaller modulus of costs for welding. Therefore, it is useful to
is made, the shape is almost always elasticity in tension as well as a smaller select welded parts at such machines which
adapted to technological practice in the modulus of elasticity in shear, therefore, are manufactured individually or in small
appropriate foundry. Then, the situation at the requirement to obtain the same numbers of pieces. There was an opinion
generally happens that a compromise rigidity it is necessary to select thicker (supported by tests with simple rods) that
must be done between technology and walls at the casting than at the part cast-iron parts damp vibrations better than
designing. The designer must keep in mind welded from sheet steel; welded ones. However, more detailed and
easy manipulation, a possibility to clean the • torsionally stressed sections cannot be deeper experiments and tests prove that
casting after it is taken out from the mould, made completely closed at castings, this opinion is not the quite right one. Joints
adequate weight, approach to machined therefore, it is necessary to select thicker in welded places act in a damping way
surfaces, casting technology, shape and walls and denser ribbing; because those parts touch there tightly which
functional correctness of the casting (rather • for technological reasons (considering move towards each other at vibrations.
straight surfaces), uniform hardening in all the casting possibilities), it is necessary Although these motions are slight ones,
casting parts, smooth transitions of walls to select bigger thickness at castings, that the friction arising at them contributes to
with rounding-off, the position at casting it should be necessary according to the damping of vibrations. The possibility to
or casting accuracy (backlash between required rigidity [Borský 1991]. perform irregular profile strengthening
subsequent castings). also contributes to damping of vibrations
The casting drawing or the working drawing [Borský 1991].
is decisive for the check of the shape, The disadvantage of welded beds and
h (mm)