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1. INTRODUCTION
The aim of this investigation is the possibilities of use of polymer concrete in building
machine tools structures. For that purpose, the NC lathe Mazak QT 10 headstock’s
housing is completely redesigned and polymer concrete constructive material has been
chosen and applied.
The available references [1, 2, 3] have shown same examples of use of polymer
concrete in substitution of cast iron in the design of machine tool beds. We have
decided to investigate the possibilities of the use of polymer concrete in main spindle
housing design due to the more demanding requirements connected with the
dissipation of temperature, damping and high accuracy of the structure. To be able to
redesign the original housing for the purpose of material substitution, we have
performed static, dynamic and thermal analysis of the structure.
The differences in the material properties (table 1) have initiated an iterative
process of redesign with the aim to achieve properties of the original design. Both
models, of original and redesigned housing are shown on figure 1.
a. Original b. Redesigned
Figure 1. Models of main spindle housing
3. THEORETICAL AND EXPERIMENTAL STUDY OF NEW DESIGN
We have performed wide numerical and experimental investigations of static, dynamic and
thermal behaviour of original and redesigned housing, part of which are presented in this article .
Modelling and processing of housing were performed with the use of ALGOR and I-
DEAS commercial packages [1]. Figure 2 shows maximal principal stresses of both
models. Comparative analyses of the statical characteristics (displacements, Von Mises,
Maximal Principal Stress, Mass and Young’s module) of both housings (original and
redesigned) are shown on figure 3. Despite worsening of Von Mises and maximal Principal
Stress the new design satisfied the limits. We have reduction of mass of redesigned housing
for approximately 50% in comparison with the original design which strongly recommend
the use
of polymer concrete [1].
a. Original b. Redesigned
We have used the same models, developed with ALGOR and I-DEAS, for
dynamic analysis of both housings [1]. The comparative analysis of Eugene
frequencies of both models is shown in figure 4. As we can see the Eugene
frequencies of polymer concrete design are twice higher then those of cast iron
design which represents certain improvement of the design. Figure 5 shown
comparative analysis of the experimental data of the damping ratio of both
designs. The results show superior performances of polymer concrete housing in
comparison with cast iron structure [1].
Figure 3. Comparative Analysis of Statical
Characteristics
Figure 4. Comparative Analysis of Dynamical
Characteristics
Figure 5. Comparative Analysis of Experimental
Damping Ratio
While two types of aggregate, ocean sand and Sierra Nevada
pea gravel, are fed into the hopper of the mixer, a pipe mixer
adds blended polyester resin. A screw-type auger thoroughly
mixes these materials then feeds them into the slip form paver
for placement.
After placing the overlay, workers use
a nuclear density tester to test its
compaction and density. Compaction
on this job averaged 99% to 100% of
the standard, exceeding the minimum
specifications of 97%. The overlay also
was tested for polyester resin content.
Results showed a content of about 11.05%.
Before choosing a resin binder, check its specifications
carefully. A good binder should have:
• A low viscosity so it’s easy to mix, place, and finish (viscosity can be varied
somewhat to accommodate different applications methods)
• A 15- to 45-minute gel time to give workers enough time to place and finish the
overlay before it cures
• No solvents or ingredients that can evaporate during curing and cause
shrinkage cracking
• A minimum bond strength to concrete of 250 psi
• A compressive strength capability of more than 5000 psi
• A tensile elongation of at least 30% and a tensile strength of more than 2000 psi
(both indicate good flexibility and resilience) Resin binders having these physical
properties can produce polymer concrete overlays with life expectancies of 20
years or more if the overlays are properly installed
Mixing polymer concrete
Poor-quality polymer concrete overlays often are the result of inaccurate proportioning
and inadequate mixing of the binder components and aggregate. Mixing the binder
components at the ratios specified by the supplier is critical. Once the components are mixed
they start a chemical reaction that continues until the polymer concrete hardens. Any
variation of the mixing ratios can result in a soft, uncured overlay. Thorough mixing of the
binder components also is important. Failure to mix the components completely can result in
a non uniform overlay with soft and hard areas.
If the premixed method of overlay placement is used (described below), aggregate must
be added to the mixed polymer binder. Again, attention to specified mix ratios and thorough
mixing are necessary to ensure uniformity. Polymer concrete components can be batch-
mixed in a convention a concrete or mortar mixer.
However, better quality control is possible by using a machine that automatically
proportions, mixes, and dispenses components. This ensures mixing accuracy and
eliminates batch-to-batch inconsistencies.
The machine should be carefully calibrated and the calibrations should be checked frequently
during machine use.
Installation methods
An easy way to test for sufficient curing is to poke the overlay with a screwd
river. If the screwd river doesn’t leave a mark, the overlay is probably ready
fortraffic. However, have the project engineer or a representative of the resin
binder supplier confirm overlay readiness before reopening the bridge deck.
Proven performance
The mixture is obtained by adding water into a clean container and then
gradually adding the powder. Add approximately 1 gallon of water for each 50 lb
bag of Polymer Concrete Patcher to be used. If the mortar becomes too difficult
to mix, add additional water until the desired consistency is achieved. The
mixing process can be performed in a cement mixer or in a bucket (working
manually or with a mechanical agitator) or using a continuous mixer until
homogeneous, lump-free mixture is obtained. It is also possible to use a sprayer
to mix and simultaneously pump the mixture, using a rotor/ stator system
suitable for the granulometric gradation of the mixture.
Hand Mixing Instructions
Empty the bags into a suitable mixing container. Add approximately 1 gallon
of water for each 50 lb bag of Polymer Concrete Patcher to be used. Work the
mix with the necessary tools, and add additional water as needed until the desired
consistency is achieved. Make sure all the material is adequately wet before
proceeding with the application.
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