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Procedia CIRP 66 (2017) 2 – 9

1st Cirp Conference on Composite Materials Parts Manufacturing, cirp-ccmpm2017

Composites in production machines

H.-C. Möhringa,*
a
Institute of Manufacturing Technology and Quality Management (IFQ),
Otto-von-Guericke-University Magdeburg, Universitätsplatz 2, 39106 Magdeburg, Germany

* Corresponding author. Tel.: +49-391-67-58552 ; fax: +49-391-67-42370. E-mail address: hc.moehring@ovgu.de

Abstract

This paper gives an overview of the design and application of composite materials in machine tools. Some exemplary machine elements, tool
structures and components are introduced and the technical potentials, requirements and challenges are discussed. The presented prototypes and
industrial products show that besides the lightweight construction aspect furthermore the specific mass related stiffness characteristics and the
advantageous damping properties as well as the thermal behavior of composite structures provide outstanding chances regarding the
improvement of the machine performance and accuracy. New degrees of freedom in machine component design and layout can be exploited
especially if material combinations are implemented.
© 2017 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
© 2017 The Authors. Published by Elsevier B.V.
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of the 1st Cirp Conference on Composite Materials Parts Manufacturing.
Peer-review under responsibility of the scientific committee of the 1st Cirp Conference on Composite Materials Parts Manufacturing

Keywords: Machine tool; Design; Material

1. Introduction elements, tool components and spindles, nowadays a rising

number of industrial implementations can be found [1] (Fig. 1
The design, manufacturing and application of composite and Fig. 2).
parts is mainly driven by the aerospace and automotive
industry. Mass reduction in order to save fuel is the
predominant goal and reason for the use of materials like
carbon fiber reinforced polymers (CFRP) or similar
composites with glass, aramid or basalt fibers. These
materials can also be combined with cellular, foam or
honeycomb cores as well as sheet metal elements. Various
composite parts manufacturing processes have been and are
still investigated and developed in order to achieve a cost
efficient realization of the composite components. During the
last two decades, a significantly increasing level of
automation can be observed that is still improving thanks to
the development work in industry and research institutions.
Against this background, applications of composite parts
become more and more interesting and relevant also in
general machine construction and especially in the machine
tool sector. Whereas for a long time, CFRP and other Fig. 1. High speed lightweight machine tool by company EEW Protec [2]
composite materials have been used predominantly in
scientific works and prototypes of machine tool structural

2212-8271 © 2017 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of the 1st Cirp Conference on Composite Materials Parts Manufacturing
doi:10.1016/j.procir.2017.04.013
 H.-C. Möhring / Procedia CIRP 66 (2017) 2 – 9
Fig. 2. High speed machining center by company MAP [3]
The lightweight construction potentials provide new
possibilities to reduce moved masses (e.g. of slides, columns,
rams), to lower inertia moments (e.g. of spindle or tool
shafts), to relieve the drive systems of the machines, to
enhance the feed motion dynamics and path accuracy, and to
improve the energy efficiency of the machine tools during
machining operations [2]. Furthermore, due to the higher
material damping properties of composite materials, increased
structural damping ratios can be achieved. In addition, the
very low or even negative thermal expansion coefficients of
CFRP parts can be utilized for a higher thermal stability of the
machines [3, 4]. As a consequence of the buildup and internal
structure of composite parts, including fibers and matrix, by
exploiting the design degrees of freedom regarding the types
of fibers, fiber orientation and layer composition, quasi-
isotropic or targeted anisotropic mechanical and thermal
characteristics can be created. This, on the other hand,
requires sophisticated design, layout and optimization
methods as well as related modelling and simulation
approaches in order to gain the full potential of the material
application but to implement an efficient design process. As
an example, Lasova et al. investigated the use of Pareto
optimization in order to find an optimal lay-up of a wound
square tube including CFRP with high modulus fibers and
cork composition damping layers [5]. Three dimensional
numerical simulations were conducted considering the static
bending stiffness, the natural frequency and the damping ratio
as optimization criterions.
Considering the huge bandwidth of mechanical fiber
properties but also of the associated price of the different
types of fibers, comprehensive design optimization strategies
must, in addition to the physical parameters, also take the
related costs of design variants into account. The crucial
question of the permitted price of a newly designed composite
3
machine component with improved properties and
performance can only be answered by an appropriate value
benefit analysis.
Another aspect of composite material application in
machine tool structures is the ability of functional integration.
Especially sensor systems can be embedded during the
composite part manufacturing processes. Furthermore,
additive manufacturing and conductive material printing
technologies allow an automated and cost efficient generation
of the necessary wiring or realization of circuitry which can
be integrated in the part production chain. By this functional
integration, the performance of composite machine tool
elements can be enhanced beyond the limits of conventional
component design.
2. The use of composites in machine structures
A fundamental aim when using composite materials in
production machinery – of course – is to reduce the mass and
inertia of moved machine elements. This can exemplarily be
seen in pick-and-place robot systems as depicted in figure 3.
In these applications, the functional requirements regarding
positioning and path accuracy are relatively low compared to
machine tools.
Fig. 3. Pick-and-place robots by Convitech (left) and KUKA (right)
In contrast, very high precision and the requirement of a
maximum dynamic stiffness and damping capacity is
demanded in metrology devices and inspection machines.
Jung et al. investigated the design of a hybrid composite-
aluminum beam structure with high modulus (HM)
carbon/epoxy composites with respect to the design of a LCD
glass panel inspection machine [6]. The layout was optimized
in terms of the cross section shape of the beam, the stacking
sequence and the thickness of the composite reinforcement
with respect to the fundamental natural frequency and bending
deformation (Fig. 4). A composite robot end effector for the
handling of LCD glass panels is introduced in [7]. The
beneficial dynamic properties of composites were exploited by
Lee et al. with respect to the design of a guiding arm of an
electrical discharge wire cutting machine [8]. With the support
of Finite Element (FE) simulations, the detailed design
regarding bonding length and number of reinforcing plies was
conducted. Compared to the conventional arm, the mass was
reduced to less than 50%, the static stiffness was maintained
and the fundamental natural frequency as well as the damping
ratio were significantly improved.
4 H.-C. Möhring / Procedia CIRP 66 (2017) 2 – 9

A hybrid steel-composite headstock for high-precision

grinding machines was analyzed by Chang et al. [9].
Especially in the higher frequency range of 100-500 Hz, the
composite reinforcement led to an improvement of the
dynamic stiffness and damping.

Fig. 5. Steel-composite hybrid headstock [9]

Suh and Lee presented the design of a hybrid material slide

structure with composite reinforcements [10, 11] (Fig. 6). The
fundamental natural frequency was increased from 64 Hz to
92 Hz and the damping factors for the first 5 modes were
enhanced by up to more than 100%.

Fig. 4. LCD inspection machine and beam cross sections [6]

Regarding the design of machine tools for cutting and

grinding machining operations, various investigations were
carried out and prototypes were built in order to achieve the
best compromise between mass reduction, static stiffness,
fundamental natural frequencies, damping ratios as well as
thermal stability. Besides more or less pure composite
structures, the majority of approaches considers hybrid
approaches in which different materials are combined.
Fig. 6. Milling machine with hybrid material slide [10]
 H.-C. Möhring / Procedia CIRP 66 (2017) 2 – 9
The strength of the adhesively bonded sandwich structure
of the horizontal moving body was analyzed in [12].
Furthermore, the thermal properties of the composite
sandwich were investigated.
In [13], carbon/epoxy composite-aluminum hybrid
structures with friction layers were applied with the aim to
achieve a high structural damping. The static deflection due to
deadweight and the first natural frequency were analyzed with
respect to the stacking angle and thickness of the composite.
Between the aluminum and composite interface, a friction
damping layer was inserted. Composite reinforcements were
also investigated in [14]. The use of composite sandwich
materials in machine tools was discussed in [15]. Composite-
foam-resin concrete sandwich structures were studied in [16].
Kulisek et al. performed case studies on rams with, on the one
hand, a thick-walled composite body and minimal amount of
steel as well as, on the other hand, a hybrid structure with fiber
composites and cork layers [17] (Fig. 7).
Fig. 7. Composite and hybrid spindle ram [17]
Fleischer, et al. and Koch et al. filled a composite machine
slide with different amounts of fluids in order to control the
structural dynamics during machine utilization [18, 19].
Examples of downscaled “desktop” machines can be seen in
[20, 21, 22] (Fig. 8).
Fig. 8. Modular machine frame for desktop machines [20]
5
A serious aspect especially for hybrid combinations of
materials with different thermal expansion coefficient
concerns thermally induced mechanical stresses in the
interfaces and joints which can lead to de-bonding and a loss
of structural stiffness. Residual stresses in material interfaces
can already occur during the curing of the composite parts.
Therefore, co-curing strategies were investigated in order to
reduce these stresses [23-26]. In [27] a thermal expansion
clamp for the reduction of residual stresses during curing is
presented.
The characteristics of composite structures are influenced
by the joints, e.g. towards metal parts as interfaces for guides,
drives or machine components. The layout of mechanically
fastened joints has to be carried out carefully in order to avoid
structural damage of the composite elements [28]. Kolesnikov
et al. provide an overview of the aspects of bolted joints in
composites and propose a hybrid material reinforcement in
order to improve the strength of the joints [29].
3. The use of composites in spindles and tools
In order to reduce the moment of inertia of spindle rotors
and tool bodies, to reduce their thermal growth and to improve
the dynamic behavior, the use of composites in spindles and
cutting tools was investigated and demonstrators as well as
first products are available (Fig. 9).
Fig. 9. Composites in metal cutting and grinding tools by Xperion
A graphite epoxy composite boring bar for chatter
reduction was introduced and further developed by Lee [30,
31]. Heisel developed a composite reamer shaft with specific
interfaces for the metal segments of the tool [32] (Fig. 10). A
mass reduction from 28.5 kg of the conventional steel tool
down to 10.5 kg of the newly designed tool, an increase of
stiffness and a significant improvement of the fundamental
natural frequency were achieved. Kim presented a hybrid
material circular plate structure for cutting tools in [33]
(Fig. 11). The constrained damping characteristics were
investigated with respect to the adhesive bonding thickness
and the use of composite or PVC foam.
Since the clamping of composite tool bars could lead to
damages and a loss of mechanical performance and strength,
6 H.-C. Möhring / Procedia CIRP 66 (2017) 2 – 9
Hwang et al. proposed a metal core or sleeve inserted in the
composite body of a tool bar [34] (Fig. 12).
Fig. 10. Modular construction of composite reamer tool [32]
Fig. 11. Hybrid material circular plate tool body [33]
Fig. 12. Composite tool bars with new design of the clamping part: (a) the
sleeve type clamping part; (b) the core type clamping part [34]
In 1985, Lee et al. presented the idea and a design approach
of a composite rotor for machine tool spindles [35]. Compared
to a steel spindle bearing system, the maximum width of cut
could be increased by 20%. Furthermore, the pre-loading
characteristics were more stable with the composite system.
Bang and Lee introduced a composite shaft of a high speed air
spindle in [36]. The stacking sequence was determined
considering the bending stiffness of the carbon composite
shaft and the static stiffness of the air bearing. In [37], the
rotor of an AC induction motor was manufactured using
magnetic powder containing epoxy composite and the motor
shaft was made of high modulus carbon fiber epoxy composite
material. A steel core was inserted into the composite rotor in
order to improve the magnetic flux. The reinforcement of a
spindle cover with carbon fiber epoxy composite material was
analyzed in [38].
4. The use of composites in clamping systems
In case that high accelerations are applied to fixtures and
clamping systems during machining operations, the goal of
mass reduction and lowered moments of inertia is also valid
for these core elements of machine tools. With respect to
accuracy issues, the low thermal expansion of composites can
be exploited within fixtures. Furthermore, regarding process
stability in cutting and grinding processes, the dynamic
stiffness and structural damping properties of the workpiece
holding systems has a significant influence. Thus, the use of
composite materials in fixtures reveals a high potential in
order to improve the overall performance of the machining
system.
In [39] the use of CFRP components as damping elements
in fixture frames was investigated (Fig. 13).
Fig. 13. Test fixtures with CFRP frame component [39]
The pure CFRP frame element shown in Fig. 13d provided
much higher natural frequencies and damping ratios than the
comparable steel element (Fig. 13c). However, the joints in
the test fixture (Fig. 13b) led to a lower dynamic stiffness of
the assembled system. Therefore, for the final prototype
fixture design, improved joints were developed and integrated
(Fig. 14).
 H.-C. Möhring / Procedia CIRP 66 (2017) 2 – 9
Fig. 14. Final fixture prototype with CFRP damping frame [39]
5. Functional integration
Composite material structures are suitable for inherent
sensor and actuator integration. On the one hand, integrated
sensors can be used for structural health monitoring [40]. In
machine tool applications, structural health monitoring of
composite parts is highly relevant. In case of overloading or
slight crashes, internal damages of CFRP parts can hardly be
detected by external measuring devices in a workshop
environment. Consequently, an inherent state observation is
required. Here it must be considered, that inacceptable
changes of structural properties are already reached, if the
static or dynamic stiffness characteristics differ from the initial
values so that the machining processes are affected in terms of
accuracy, workpiece surface defects or instable cutting
conditions.
Fig. 15. Integration of fiber optic Bragg sensors in composite ram [41]
7
Integrated sensors also provide relevant information for
machine and process state monitoring. Meo et al. integrated
fiber optic Bragg strain sensors into a ram of a vertical milling
center in order to gather bending deformations and tool
displacements during the process [41] (Fig. 15). In [42] and
[43], piezo ceramic sensors are embedded in composite
machine components. A printed circuit is integrated in [42] in
order to realize the wiring of distributed sensors within the
analyzed test specimen. Brecher et al. exploit the thermal
stability of CFRP rods for a direct integrated measuring device
for thermal state monitoring and compensation of thermally
induced machine deflections [44]. The application of piezo
sensor integrated CFRP structures in a workpiece clamping
intelligent chuck system is introduced in [45] (Fig. 16). The
sensory piezo patch transducers are embedded in CFRP
fingers which are pre-stressed against the workpiece during
the clamping setup. Due to their high sensitivity, the sensors
are capable to measure workpiece vibrations during the
milling operations. By this, process monitoring regarding
chatter occurrence becomes possible as well as an adaptive
control of countermeasures (e.g. targeted counter excitation).
Figure 17 shows exemplary signal frequency spectra for the
three integrated sensors (PZT1…PZT3) which were obtained
during a milling test process.
Fig. 16. CFRP integrated piezo sensors in an intelligent chuck [45]
Fig. 17. Frequency spectra obtained by CFRP integrated sensors
8 H.-C. Möhring / Procedia CIRP 66 (2017) 2 – 9
6. Conclusions
This paper gives an overview of the application of
composite materials in production machines. As a summary,
especially carbon fiber reinforced polymer materials can be
found in robot and machine tool structural components,
spindles and tools as well as in fixtures. The advantageous
material properties of low specific weight, high mass related
specific stiffness, high material damping, low thermal
expansion and functional integration capability have already
been utilized in various exemplary implementations,
prototypes and products. This shows that new degrees of
freedom in production machinery design are provided by
composite materials. However, the material costs as well as
the requirement of automated and reproducible manufacturing
processes for precision parts in the machinery sector are
challenges that have to be solved. So far, predominantly
individual machine components were realized in single piece
or small batch production environments. In order to
implement the material technology in machine tool industry,
medium batch scenarios up to mass production strategies are
necessary. Furthermore, structural health monitoring systems
are required in order to enable an observation of the material
and structural properties of machine components during their
long term usage. Especially if overload or collision situations
occur, the reliability of the structural performance has to be
assessed. Finally, influences of chips and coolant lubricant
have to be considered carefully in component design.
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