Analysis of the Coupled Vibration Between Feed Drive Systems and Machine Tool Structure
Ryuta Sato*, Gen Tashiro**, and Keiichi Shirase*
*Department of Mechanical Engineering, Kobe University
1-1 Rokko-dai, Nada, Kobe 657-8501, Japan
52 Ishizu-Kitamachi, Sakai, Osaka 590-0823, Japan
In this study, we have constructed a mathematical model that can analyze the coupled vibration of machine tool structure and feed drive systems. The model is proposed on the basis of the modal analysis of the actual machine tool structure. It consists of three translational and three rotational displacements of the bed, relative angular deformations between the bed and column, relative translational and angular deformations between the bed and saddle, and relative translational and angular deformations between the column and spindle head. In addition, each feed drive system is modeled using a vibration model, which has two degrees of freedom. The servo controllers of each axis are also modeled. To confirm the validity of the proposed model, frequency responses, motion trajectories of the feedback positions, linear scale positions, and the relative displacement between the table and head are measured and simulated. The effect of coupled vibrations on the tracking errors is examined with the help of both experiments and simulations. To investigate the effect of the servo systems on the vibration, both experiments and simulations are carried out by using feed drive systems in the following three conditions: mechanically clamped, servo-on, and servo-off. The results of experiments and the simulations show that the proposed model can express the mode of vibration and the influence of the condition of feed drive systems on the mode of vibration.
-  W. R. Moore, “Fundamentals of Mechanical Accuracy,” The Moore Special Company, 1970.
-  ISO230-1, “Test Code for Machine Tools – Part I: Geometric accuracy of machines operating under no-load or quasi-static conditions,” 2012.
-  S. Ibaraki and W. Knapp, “Indirect Measurement of Volumetric Accuracy for Three-axis and Five-axis Machine Tools: A Review,” Int. Journal of Automation Technology, Vol.6, No.2, pp. 110-124, 2012.
-  Y. Altintas, A. Verl, C. Brecher, L. Uriarte, and G. Pritschow, “Machine Tool Feed Drives,” CIRP Annals – Manufacturing Technology, Vol.60, No.2, pp. 779-796, 2011.
-  R. Sato, “Feed Drive Simulator,” Int. Journal of Automation Technology, Vol.5, No.6, pp. 875-882, 2011.
-  R. Sato and M. Tsutsumi, “Modeling, and Controller Tuning Techniques for Feed Drive Systems,” Proc. of the ASME Dynamic Systems and Control Division, Part A, DSC-Vol.74-1, pp. 669-679, 2005.
-  R. Sato and M. Tsutsumi, “High Performance Motion Control of Rotary Table for 5-axis Machining Centers,” Int. Journal of Automation Technology, Vol.1, No.2, pp. 113-119, 2007.
-  K. Nishio, R. Sato, and K. Shirase, “Influence of Motion Errors of Feed Drive Systems on Machined Surface,” Journal of Advanced Mechanical Design, Systems, and Manufacturing, Vol.4, No.6, pp. 781-791, 2012.
-  Y. Sato, R. Sato, and K. Shirase, “Influence of Motion Error of Feed Drive Systems onto Machined Surface Generated by Ball End Mill,” Journal of Advanced Mechanical Design, Systems, and Manufacturing, Vol.8, No.4, No.14-00085, 2014.
-  R. Sato, Y. Sato, K. Shirase, G. Campatelli, and A. Schippa, “Finished Surface Simulation Method to Predict the Machine Tool Motion Errors,” Int. Journal of Automation Technology, Vol.8, No.6, pp. 801-810, 2014.
-  F. Rehsteiner, S. Weikert, and Z. Rak, “Accuracy Optimization of Machine Tools under Acceleration Loads for the Demands of High-Speed-Machining,” Proc. of the ASPE Annual Meeting, St. Louis, pp. 602-605, 1998.
-  A. Matsubara, M. Umemoto, M. Hamanuma, J. Fujita, Y. Kai, and Y. KakiNo.“Feed Drives of NC Machine Tools Influenced by Base Vibration (1st Report), – Modeling and Servo Analysis of Feed Drives with Base Dynamics –,” Journal of the Japan Society for Precision Engineering, Vol.70, No.4, pp. 583-587, 2004 (in Japanese).
-  B. Bringmann and P. Maglie, “A method for Direct Evaluation of the Dynamic 3D Path Accuracy of NC Machine Tools,” CIRP Annals – Manufacturing Technology, Vol.58, No.1, pp. 343-346, 2009.
-  K. Nagaoka, A. Matsubara, T. Fujita, and T. Sato, “Analysis Method of Motion Accuracy Using NC System with Synchronized Measurement of Tool-Tip Position,” Int. Journal of Automation Technology, Vol.3, No.4, pp. 394-400, 2009.
-  M. Steinlin, S. Weikert, and K. Wegener, “Open Loop Inertial Cross-talk Compensation Based on Measurement Data,” Proc. of the 25th Annual Meeting of the ASPE, Atlanta, No.3079, 2010.
-  Y. Altintas, C. Brecher, M. Weck, and S. Witt, “Virtual Machine Tool,” CIRP Annals – Manufacturing Technology, Vol.54, No.2, pp. 115-138, 2005.
-  O. Zirn, “Machine Tool Analysis –Modelling, Simulation and Control of Machine Tool manipulators,” A Habilitation Thesis, Department of Mechanical & Process Engineering ETH Zurich, 2008.
-  D. Kono, T. Lorenzer, S. Weikert, and L. Wegener, “Evaluation of Modelling Approaches for Machine Tool Design,” Precision Engineering, Vol.34, pp. 399-407, 2010.
-  D. Kono, S. Weikert, A. Matsubara, and K. Yamazaki, “Estimation of Dynamic Mechanical Error for Evaluation of Machine Tool Structures,” Int. Journal of Automation Technology, Vol.6, No.2, pp. 147-153, 2012.
-  D. Kono, S. Nishio, I. Yamaji, and A. Matsubara, “A Method for Stiffness Tuning of Machine Tool Supports Considering Contact Stiffness,” Int. Journal of Machine Tools & Manufacture, Vol.90, pp. 50-59, 2015.
-  A. Scippa, N. Grossi, and G. Campatelli, “Milled Surface Generation Model for Chip Thickness Detection in Peripheral Milling,” Procedia CIRP, Vol.8, pp. 450-455, 2013.
-  M. Law, A. S. Phani, and Y. Altintas, “Position-Dependent Dynamic Modeling of Machine Tools Based on Improved Reduced Order Models,” ASME Journal of Manufacturing Science and Engineering, Vol.135, No.MANU-12-1033, 2013.
-  M. Law, Y. Altintas, and A. S. Phani, “Rapid Evaluation and Optimization of Machine Tools with Position-dependent Stability,” Int. Journal of Machine Tools & Manufacture, Vol.68, pp. 81-90, 2013.
-  C. J. Kim, J. S. Oh, and C. H. Park, “Modelling Vibration Transmission in the Mechanical and Control System of a Precision Machine,” CIRP Annals – Manufacturing Technology, Vol.63, pp. 349-352, 2014.
-  C. H. Lee, M. Y. Yang, C. W. Oh, T. W. Gim, and J. Y. Ha, “An Integrated Prediction Model Including the Cutting Process for Virtual Product Development of Machine Tool,” Int. Journal of Machine Tools & Manufacture, Vol.90, pp. 29-43, 2015.
-  VDI Guidelines, “Systematic Calculation of High Duty Bolted Joints,” VDI 2230, 1977.
-  M. Yoshimura and A. Fukano, “Identification of Spring Stiffness and Damping Coefficient in Machine Tool Joints,” Journal of the Japan Society for Precision Engineering, Vol.45, No.12, pp. 1418-1424, 1979 (in Japanese).
This article is published under a Creative Commons Attribution-NoDerivatives 4.0 International License.