WEIGHT DEFORMATION

By Bharath Ram
Roll No:4
COLLEGE OF ENGINEERING TRIVANDRUM
 Introduction
• Methodologirs are developed to allow the estimation of the magnitude
of an error source and its contribution to dimension, form or surface
characteristics of a workpiece.
• In general, the error terms considered were “macroscopic” in nature.
• They dealt with the kinematic errors in machine axes and
components, thermal errors as well as system error, for example, the
resolution of an encoder feeding back positional information.
• In this study we will delve a little deeper into other sources of error in
manufacturing – Weight Deformation
• We are addressing the static and dynamic stiffness of machines. That
is, static deflection under the load of machining (and the sensitivity of
the position of the load in the machine tool loop) and dynamic
deflection under the varying periodic as well as non-periodic influence
of the manufacturing process and other machine components.
• Since all machines are elastic structures at some level of observation,
the effect of these static and dynamic forces and influences will be
seen in the dimension, form or surface characteristics of a workpiece
• The design of machine structures (from machine tools to
lithography machines) is influenced by performance criteria that
can be summarized in the following four categories.
• Weight deformation – changes in the form or shape of the structure as
a result in movement of workpieces or machine components
(headstocks, tables, etc.)
• Cutting force deformation – since the machine tool (in cutting) acts as
a “structural loop,” the forces applied to this loop will cause
deformation. Hence, when the cutting process generates forces during
chip formation, those forces will cause deformation of the
loop structure.
• Forced vibrations – periodic forces due to machine action (rotation of
slightly eccentric component, for example) or from external
environmental sources
• Self-excited vibrations (chatter) – conditions within the machining
process can generate vibrations. This is usually more prominent at
heavier depths of cut.
 Weight Deformation
• While previous studies have discussed foundation displacement due
to weight of components and compliance of joints, ways and
bearings, we add here only the effect on the workpiece of weight
deformations.
• Figure 1 illustrates, for several machine tool configurations, the effect
of weight deformations. In Figure 1.a, the cross support rail of a plane
mill (as used for milling spar structures in aerospace products) both
bends and twists due to the manner in which the head is mounted on
the rail.
Fig 1: Weight deformation effects on a number of machine tools, a) plane milling machine,
b) jig boring machine, c) vertical boring machine, and d) horizontal milling machine
• Pay special attention to the effect on the plane of the surface of the
workpiece of these deformations. The component deformation can
result in non-planar surface creation (from bending) as well as more
localized surface finish effects due to the non-perpendicular cutting
tool axis orientation in Figure 1.d, for example, due to torsion
• An extreme case is seen in Figure 1.d with a machine tool with a
horizontal “cantilevered” spindle support arm. As expected, movement
of the spindle head towards and away from the machine column will
cause varying deviation in the position of the spindle head.
• There can be an interaction between the shifting weight of a machine
during operation, its foundation and resulting structural errors due to
deformation, Figure 2.

Figure 2: Weight deformation of a boring machine

• The table deformation due to motion along the y axis will result in
varying distances and orientations of the tool relative to the workpiece
in x-y (usually a cylindrical feature being produced). The machine
saddle deforms and the bed twists
• Depending on the number and location of support pads for the
machine base, the machine will experience deviations between the
spindle and workpiece (changing with the z-location).
 REFERENCES
• Tonshoff, H., Lectures on Machine Tools Dynamic Behavior, UC-
Berkeley, March, 2001.
• Tlusty, J., “Criteria for Static and Dynamic Stiffness of Structures,”
Volume 3, Machine Tool Mechanics of the Technology of Machine
Tools - Machine Tool Task Force Study, Lawrence Livermore National
Laboratory, October 1980.