Applicants: Gligorce Vrtanoski

Vladimir Dukovski
Representative: BERIN Ltd.

DESIGN OF POLIMER CONCRETE MAIN SPINDLE

HOUSING FOR CNC LATHE

DESCRIPTION OF INVENTION

Field of technique to which invention relates

The invention relates to the field of manufacturing processes. According to the

International Classification of Patents (ICP) the invention can be related to the
machine tool’s class; metal working not related to other, for subclass of elements,
components or accessories for machine tools; machine tools in general,
characterizing with design of single elements or components; combination or sum of
machines for metalworking, not directed to some results. In narrow meaning, the
invention relates to the group of elements belonging to the general elements for
building machines, especially relatively big, fixed parts, e.g. subgroup of frames,
beds, columns end similar components. According the international patent
classifications, the invention can be labeled with B23Q1/01.

Technical problem which is solved with the invention

With this invention the problem of improvement of physical and mechanical

characteristics of the standard main spindle housing design made of cast iron,
substituted with polymer concrete, has been solved. This leads to the reduction of
mass, improvement of damping, natural frequencies and the coefficient of thermal
linear expansion with the appropriate for practice stiffness.
Also, the reduction of tool development and production time and the flexibility
for product changes has been achieved.
 Beside all these the polymer concrete housing demonstrates significantly
better economic indicators, in comparison with the cast iron design, such as: reduced
overall cost, reduction of production time, reduced capital investment cost and
reduced maintenance cost.
Particular advantages off polymer concrete housing are in the area of
environment protection with its 100% recycling possibility. The cast iron products can
be recycled to the certain degree, with waste consumption of energy and not –
ecological recycling. In the recycling of polymer concrete structures the only waste of
energy is for crumbling of material in small peace further used as fillers in polymer
concrete structure.

Actual trends in the technique

The machine tool is a complex system composed of many single individual

components. The requirements for the accuracy of machining and increased
productivity are driving forces for fast development in the field of design and control
of machine tools. Besides the development of new design solutions and CNC control
of machine tools, the selection of constructive material is till now very important
issue. For appropriate selection of constructive material, understanding and knowing
the performance features and characteristics of machine tools is required.
Very big influence on the performance of machine tools demonstrates: the
machining conditions, external loads, stress-strain state, vibrations and thermal
behavior. Static and dynamic characteristics of structure, represented by static and
dynamic stiffness, dominantly influence the accuracy of the machine tools.
The machine tool’s structure is composed of several substructures and
elements, for example, beds, columns, housings, tables and other mechanical
components. The main spindle housing is permanently under variable load and
thermal conditions and under those conditions it has to assure precise mutual
position of the tool and workpiece, which is demonstrated by form and dimensions of
the workpiece errors. The most dominant influence factor, which finally determines
those errors, is the material of the housing. The main requirements that this material
has to fulfill are: thermal stability, high stiffness, vibro-stability, high damping and low
specific density, as well as appropriate production technology and cost.
 DESCRIPTION OF THE TECHNICAL PROBLEM SOLUTION

Having in mind technical and technological requirements for the main spindle
housing, its production and functioning, first a redesign of the geometry is required.
The changes in the design of the housing are shown on the following figures:
Figure 1 – Half-cut of the housing
Figure 2 – Front cut of the housing
Figure 3 – Middle cut of the housing
Figure 4 – Rear cut of the housing
where with the broken lines, the cuts of the original housing are shown. For more
detailed explanation of the technical problem, the following figures are also
presented:
Figure 5 – Comparative analysis of volumes and masses
Figure 6 – View of the original design of the housing
Figure 7 – View of the redesigned housing
Figure 8 – Comparative static analysis
Figure 9 – Comparative dynamic analysis
Figure 10 – Comparative thermal analysis
Figure 11 – Phases of puling out of the housing from the tool
Figure 12 – View of the housing after casting
From the presented figures 1 to 4 (Fig.1 to Fig.4) it is evident that the
geometry of the original design has transformed in more simple shape which
influents the cost of casting tool and simplify the assembly of the main spindle unit.
Figure 5 represents comparative analysis of the volumes. It is evident that the
overall volume of the new design has increased for 33.17%, but the mass has
reduced for 41.17%. Figure 6 represents the original design and the new one. The
figure 7 represents redesigned housing made of polymer concrete with metal rings
and front metal plate.
With the purpose for comparison of mechanical and physical characteristics of
housings made of cast iron and polymer concrete, a comparative analysis has been
performed.
The comparative static analysis has the intention to compare stress – strain
state of both housings, with the following values: maximal principal stress, von Mises
criteria and displacements. Compared values are graphically presented on figure 5.
The cast iron housing has a 50% bigger mass than polymer concrete housing. This
leads to better manipulation of the housing during the assembly process.
The static analysis presented on Figure 8, shows that the maximal principle
stress values according to von Mises and maximal displacements of cast iron
housing are very low in comparison with those of polymer concrete housing. Those
values of polymer concrete housing deformation are within required values, which
allowed having reasonable size of the housing and appropriating casting conditions.
The safety factor of the polymer concrete housing, defined with the principle
stresses, is 65% above the bending strength of polymer concrete.
The comparative analysis of dynamic performances compares natural
frequencies of both housings. Figure 9 graphically shows first 6 (sixth) values of
natural frequencies. The analysis shows that polymer concrete housing
demonstrates twice-bigger values of natural frequencies and three times bigger
damping, which leads to better dynamic characteristics.
Comparative thermal analysis has the aim to compare calculated maximal
temperatures in both housings and, also, to show thermal-stress-strain status. The
figure 10 shows the maximal values of temperature, stresses and displacements
under maximal temperature and normal room temperature.
The analysis of the results of numerical calculation shows that the maximal
temperature of the original housing is approximately 3% lower than the redesigned
housing. With the addition of holes and simulation of natural convection, the
temperature of the polymer concrete housing can be reduced for further 25%, which
ca leads to a very good thermal behavior. Heat distribution of the temperature in the
original housing is uniform, within the limits of 1oC, which shows that the temperature
is evenly distributed. This means that there is a possibility for fast conductivity of
temperature toward the bed of the machine and its thermal deformation. The
distribution of temperature in redesigned housing is non-uniform with the temperature
differences between the heat sources and the housing bases of 16oC, which leads to
the conclusion that polymer concrete conduct very slow the temperature toward the
machine bed.
The design process of the casting tool for polymer concrete housing takes in
account redesigned geometry and the way of producing appropriate structure of
polymer concrete. Also, as major criteria during the selection of appropriate structure
is the requirements for high accuracy of the housing (within the limits of ±0.1mm to
±0.5mm). With the implementation of the above criteria a combination of steel and
aluminum tool has been designed. During the designing process the technological
holes, tapering of inner sides (+2o) and the opening of the tool has been specially
considered. With the aim to achieve high flexibility and universality and reduction of
the tool cost for both design variants (4600rev/min and 6000rev/min), the design
process uses a special methodology for designing universal end low cost tools.
The Figure 11 shows several phases of puling out of the housing from the tool.
The measurements of the geometric dimensions of the produced polymer concrete
housing have shown high accuracy of the dimensions, within the tolerant limits of
±0.1 to ±0.5mm. Also, the normality between front surface and base surface was
0.008mm and the centricity of metal rings was within the limits of 0.003 to 0.005mm.
The achievement of such high accuracy was possible only with the use of high
precision machining and temperature stability during the machining process.
Figure 12 shows the polymer concrete housing after finishing the casting
process.

Applicants: Gligorce Vrtanoski

Vladimir Dukovski
Representative: BERIN Ltd.
 PATENT REQUIREMENTS

1. The polymer concrete main spindle housing of CNC lathe is

characterized with its design obtained with redesigning of geometry of
original cast iron design (fig.6, pos.1) as presented on figures 1 to 4.; the
overall volume of the redesigned housing has increased for 33.17%
(fig.7, pos.2) and mass has reduced for 41.17% (fig.5); the material of
original housing (cast iron) (fig.2, pos.12), has been substituted with
polymer concrete and cooling ribs avoided (fig.6, pos.3 and fig.1, pos.11)
and complicated asymmetric geometry form has been substituted with
simple one (fig.3, pos.5).
2. The polymer concrete main spindle housing for CNC lathe is
characterized with metal rings (fig.7, pos.7 and fig.12, pos.13) caste in
the main spindle bearings holes (fig.6, pos.6.) and the front face and the
base of the housing made of metal (fig.4, pos.8, fig.12, pos.14).
3. The polymer concrete main spindle housing for CNC lathe is
characterized with normality between front surface (fig.4, pos.9) and
base surface (fig.4, pos.10) equal to 0.008mm and centricity of the metal
rings (fig.7, pos.7) within the limits of 0.003mm to 0.005mm.
4. The polymer concrete main spindle housing for CNC lathe is
characterized with the maximal displacement of polymer concrete
housing of 0.0079mm, von Mises 14.8N/mm2, maximal principal stress
13.5N/mm2, mass 62.92kg and Module of Elasticity 2.8 104N/mm2 (fig.8).
5. The polymer concrete main spindle housing for CNC lathe is
characterized with twice bigger natural frequencies (fig.9) and three time
bigger damping in comparison with the cast iron housing.
6. The polymer concrete main spindle housing for CNC lathe is
characterized with different thermal characteristics in comparison with
the original one (fig.10).
7. The polymer concrete main spindle housing for CNC lathe is
characterized with combination of steel and aluminum material for its
tool design, with tapering of inner sides of 2o and special opening; the
puling out of the housing is performed in several phases (fig.11).
Applicants: Gligorce Vrtanoski
Vladimir Dukovski
Representative: BERIN Ltd.
Figure 1 Figure 2

Figure 3 Figure 4
 Figure 5

3 1

Figure 6
2 7

Figure 7

Figure 8
Figure 9

Figure 10
Figure 11

Figure 12
 Abstract

Having in mind the technical and technological aspects of the main spindle housing,
its production process and functioning, the first step of the design process is
redesigning of the geometry of original cast iron design, which leads to the increasing
of the housing volume for 33.17% and mass reduction for 41.17% (fig.5). The
polymer concrete main spindle housing for CNC lathe is casted in the universal tool
made by combination of steel and aluminum. Normality between front surface and
base surface of housing is 0.008mm, centricity of the metal rings is in the limits of
0.003mm to 0.005mm. The polymer concrete main spindle housing demonstrates
twice higher natural frequencies (fig.9) and three time bigger damping absorption in
comparison with the cast iron housing. With the addition of cooling holes a better
heat conduction has been achieved which leads to the better temperature distribution
in comparison with the cast iron housing. Beside all these the polymer concrete
housing demonstrates significantly better economic indicators, in comparison with the
cast iron design, such as: reduction of the overall cost, production time, capital
investment cost and maintenance cost. Particular advantages off polymer concrete
housing are in the area of environment protection with its 100% recycling possibility.
The cast iron products can be recycled to the certain degree, with waste
consumption of energy and non-ecological recycling. In the recycling of polymer
concrete structures the only waste of energy is for crumbling of material in small
peace further used as fillers in polymer concrete structure.

Applicants: Gligorce Vrtanoski

Vladimir Dukovski
Representative: BERIN Ltd.