Beruflich Dokumente
Kultur Dokumente
(2008) 2:219–223
DOI 10.1007/s11740-007-0074-0
MACHINE TOOL
Received: 26 April 2007 / Accepted: 25 October 2007 / Published online: 22 November 2007
Ó German Academic Society for Production Engineering (WGP) 2007
Abstract The performance of a machine tool is primarily Based on the state-of-the-art technologies, several
determined by its static and dynamic behavior. During a methods are applied on machine tools in order to
cutting process, high static and dynamic forces may occur, compensate the axis-parallel static deformations. These
which cause instabilities in the cutting process. The compensation methods are mainly based on the detection
structure integrated adaptronical compensation modules of the error of an axis at the TCP and subsequent correction
introduce a new approach to compensate static and through the axis drive. On three axis machine tools, angular
dynamic deformations of structure components of a deviations and tilts of structure components cannot be
machine tool and help in achieving a significant improve- compensated using feed drive motions [1].
ment of the process behavior. For systems applied for the active vibration compensa-
tion developed in the context of research activities, the
Keywords Machine tool Simulation Damping main focus was on the control. The placement and
arrangement of the actuators were mostly chosen intui-
tively and were not included in the focus of the research [2,
1 Introduction 3]. Transferring active systems, which are primarily
developed for light-weight and mechanically flexible
Metal cutting machine tools have to bear high static and structures (e.g. for aerospace components) into applications
dynamic loads during a machining process. The resulting for structure components of a machine tool is not directly
displacements, especially at the tool centre point (TCP), possible. The resulting static and dynamic forces on
should be as small as possible in order to ensure a high machine tool structures require much higher compensation
machining accuracy. Today’s increasing requirements forces than required for common applications mentioned
concerning productivity and capability of machine tools above [4]. Hence, greater importance should be attached to
lead inevitably to machine concepts that allow higher the selection of appropriate actuator principals, as well as
velocity and acceleration while achieving higher machin- to the choice of the accurate force transmission points.
ing quality. The structure mechanic behaviors of In the framework of a project funded by the German
components that are in the force flux play a major role to Research Foundation (Deutsche Forschungs- gemeinschaft,
fulfil these requirements. A high static and dynamic stiff- DFG), in the program 1156 ‘‘Adaptronics for Machine
ness and maximum possible system damping should be Tools’’, structure integrated adaptronical compensation
achieved in combination with a light-weight design of the modules that are able to compensate static, dynamic, as
moved structure components. well as thermal deformations of structure components of
machine tools are developed and analyzed.
With the help of these compensation modules, com-
pensation forces are applied into the structural parts of
C. Brecher D. Manohran (&) E. W. E. Stephan Witt
machine tools in order to achieve an active compensation
Laboratory of Machine Tools and Production Engineering,
Steinbachstraße 19, 52074 Aachen, Germany effect of the occurring natural deformations. The different
e-mail: d.manoharan@wzl.rwth-aachen.de configurations of these compensation systems will be
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220 Prod. Eng. Res. Devel. (2008) 2:219–223
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Prod. Eng. Res. Devel. (2008) 2:219–223 221
1500
1 Base 4 Fixture 7 Slide
Fs Fs Fs Fs
2 Column 5 Headstock 8 Guideways
3 Drives 6 Main spindle case 5 case 6 case 7 case 8
Box-in-Box-Machine Fk
Fk Fk
Load case Fx Deformation rates ∆x
11% 11% Fs Fk
6%
3 6 1 14% stiffness
8 4 kyy= 27 N/µm
5 7
2 sheet thickness
= 14 mm
16% 16%
19% top-bottom sheet
= 30 mm Fs Fs Fs Fs
1 Bed 4 Fixture 7 Column
2 Y-Slider 5 X-Slider 8 Guideways
3 Drives 6 Main spindle
Fig. 3 Compensation forces on a z-slider
Portal Machine
The analysis of the configuration of the reset forces on
Load case Fx Deformation rates ∆x
10% 8%
the above depicted z-slider structure shows that the actu-
6%
6% 8 3
6 1 ator configuration as shown in case 8 (Fig. 3) enables an
5 4
2
7 effective compensation of occurring bending deformations
10%
11%
8%
41% in an axis. In comparison to the other configuration cases,
the transmission factor Ü between the process force FS and
1 Base 4 Z-Slider 7 Cross
2 Cross slider 5 Guideways -beam the required compensation force FK is, in this case, at its
8 Drives
3 B-Axis 6 Main spindle lowest. Figure 4 shows exemplarily for the case 8 the
required force conditions for a complete axis parallel
Fig. 2 Weak spot analysis on simulation models compensation, as well as an angular compensation at the
TCP.
As shown in Fig. 4, actuators have to apply nine times
an effective way to determine the optimal placement of the the process force (applied at the TCP) in order to com-
compensation modules in a machine structure. In order to pletely compensate the occurring axis parallel
evaluate the effectiveness of different compensation strat- deformations. The force transmission factor Ü for a com-
egies, different calculations were conducted with a finite- plete angular deformation compensation amounts to 6.3.
element-model of a slider structure that complies in its Besides the technological properties of the selected
dimensions and properties with a z-slider of a gantry- actuator principal, the integrability into a machine tool as
machining centre. The different configurations of the well as the economic efficiency is an important assessment
compensation forces for this analysis are shown in Fig. 3. criterion for the industrial usage of such active compen-
The TCP of the slider model was loaded with a force of sation systems. Based on the above mentioned analysis and
Fs = 500 N for this analysis, since the developed append- assessment criteria, a detailed characterization of different
ages are of special relevance for high precision finishing actuator types with regard to their applicability in the
operations. The accuracy and surface quality for rough compensation modules was conducted. The technological
machining processes are rather circumstantial. criteria considered were the actuator forces, the stroke and
The occurring deformations due to the process force on the frequency range, wherein the actuators should apply the
the TCP were compensated with varying compensation required forces. Due to the sensory properties, which allow
forces FK on the simulation model. The aim was to deter- the actuator to also be used as a sensor, and considering the
mine the transmission ratio Ü between the process or higher dynamic actuating forces, piezo elements were
disturbing force FS and the compensation force FK for selected as actuators for the compensation modules. The
different configurations and placements of the compensa- effective integration of actuator or measurement systems
tion forces. By doing so, the best possible configuration and near the TCP is often very challenging. The compact size
combination of compensation forces as well as the amount of piezo actuators eases the integration of the compensation
of the compensation forces dependent on arrangement and systems into machine tool structures. The demands con-
orientation of the compensation modules were determined. cerning compensation forces, stroke as well as low reaction
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222 Prod. Eng. Res. Devel. (2008) 2:219–223
time (for the compensation of dynamic forces) can be can be ensured only through a detailed analysis in the
fulfilled by piezo actuators that are available on the market. conceptual phase.
For the verification of the simulations on a z-slider dem- Coupled flexible multi body simulations (MBS) are
onstrator, piezo stack translators will be used. applicable to a high degree for such an analysis. Here, the
structural mechanic behavior of the machine component in
the multi body simulation environment and the control
5 The coupled simulation behavior of the actuators in the Computer Aided Control
Engineering (CACE) environment can be coupled in the
Besides the fulfillment of technological boundary condi- time domain.
tions, the entire behavior of the control system is of In order to model the adaptronical compensation mod-
particular importance while developing such adaptronical ules, a linear piezo actuator model for a small signal range
compensation modules. An optimal design of such systems was built up in the simulation environment using MAT-
LAB/Simulink1. It was verified with metrological
investigations of a piezo actuator. In addition to this, a
compensation force FK hysteresis model was built based on the work of Schugt and
Deformation due to
Fk
Deformation due to
Angular compensation Ü = 6.3 TCP of the z-slider structure a cascade force of 500 N was
applied and the occurring angular deformation was cap-
tured and compensated with the help of the piezo actuator
and a proportional controller.
l Rest
x The results of the coupled simulation are shown in
Fig. 6. The graph at the top of the figure shows the incli-
Fig. 4 Axis parallel and angular compensation (case 8) nations at the TCP of the z-slider structure with and
at TCP
Compensation
forces
Linear piezo
actuator model
Process forces
TCP Excitation at the TCP
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Prod. Eng. Res. Devel. (2008) 2:219–223 223
2000
The implementation and analysis of compensation modules
with the entire control in a complete machine model will be
an additional task. Furthermore, a demonstrator will be
1000 designed in order to verify the capability of the compen-
Load at the TCP: 500N sation systems in practical tests.
The objective is to develop effective compensation
possibilities with robust control strategies for practical
0,0 0,5 1,5 2,0
Time [sec] applications in metal cutting machine tools and to verify
them with real machine components. If the strategy suc-
Fig. 6 Results of the coupled simulation ceeds, it will open up new possibilities for applying further
methods for light-weight design than commonly used and
methods currently in practice. This would also enable
without compensation. The simulated process force on the fulfillment of the demands concerning, on one hand, high
TCP and the required compensation forces, which are velocities, accelerations, and resulting higher jerk values
applied by the piezo actuators, are shown on the second with lower masses of the components, and on the other
graph in the figure. The occurring inclination on the TCP is hand, higher static and dynamic stiffness of the structure
completely compensated with the help of the compensation components.
modules.
The applied forces of the compensation modules are
nearly identical with the finite element calculation of the References
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