Prod. Eng. Res. Devel.
(2008) 2:219–223
DOI 10.1007/s11740-007-0074-0
MACHINE TOOL
Structure integrated adaptronical systems for machine tools
C. Brecher Æ D. Manohran Æ E. W. E. Stephan Witt
Received: 26 April 2007 / Accepted: 25 October 2007 / Published online: 22 November 2007
© German Academic Society for Production Engineering (WGP) 2007
Abstract The performance of a machine tool is primarily
determined by its static and dynamic behavior. During a
cutting process, high static and dynamic forces may occur,
which cause instabilities in the cutting process. The
structure integrated adaptronical compensation modules
introduce a new approach to compensate static and
dynamic deformations of structure components of a
machine tool and help in achieving a significant improve-
ment of the process behavior.
Keywords Machine tool · Simulation · Damping
1 Introduction
Metal cutting machine tools have to bear high static and
dynamic loads during a machining process. The resulting
displacements, especially at the tool centre point (TCP),
should be as small as possible in order to ensure a high
machining accuracy. Today’s increasing requirements
concerning productivity and capability of machine tools
lead inevitably to machine concepts that allow higher
velocity and acceleration while achieving higher machin-
ing quality. The structure mechanic behaviors of
components that are in the force flux play a major role to
fulfil these requirements. A high static and dynamic stiff-
ness and maximum possible system damping should be
achieved in combination with a light-weight design of the
moved structure components.
· Manohran (&) E. W.
C. Brecher D. · E. Stephan Witt
Laboratory of Machine Tools and Production Engineering,
Steinbachstraße 19, 52074 Aachen, Germany
e-mail: d.manoharan@wzl.rwth-aachen.de
Based on the state-of-the-art technologies, several
methods are applied on machine tools in order to
compensate the axis-parallel static deformations. These
compensation methods are mainly based on the detection
of the error of an axis at the TCP and subsequent correction
through the axis drive. On three axis machine tools, angular
deviations and tilts of structure components cannot be
compensated using feed drive motions [1].
For systems applied for the active vibration compensa-
tion developed in the context of research activities, the
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,
3]. Transferring active systems, which are primarily
developed for light-weight and mechanically flexible
structures (e.g. for aerospace components) into applications
for structure components of a machine tool is not directly
possible. The resulting static and dynamic forces on
machine tool structures require much higher compensation
forces than required for common applications mentioned
above [4]. Hence, greater importance should be attached to
the selection of appropriate actuator principals, as well as
to the choice of the accurate force transmission points.
In the framework of a project funded by the German
Research Foundation (Deutsche Forschungs- gemeinschaft,
DFG), in the program 1156 ‘‘Adaptronics for Machine
Tools’’, structure integrated adaptronical compensation
modules that are able to compensate static, dynamic, as
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
machine tools in order to achieve an active compensation
effect of the occurring natural deformations. The different
configurations of these compensation systems will be
13
220 Prod. Eng. Res. Devel. (2008) 2:219–223

analyzed to determine how the structural mechanic FActuator1,...n

Compensation
Offset- intrusion
behavior of a machine tool can be improved. The analyses of setpoint setting module
of the feed drives
are first conducted with the help of simulations. In the next
research step, the practical feasibility and the effectiveness
of the structure integrated adaptronical compensations Axis parallel
dynamic error
error
modules will be tested with the help of a demonstrator and
FActuator Xdyn, Ydyn, Zdyn
the results of the simulation analysis will be verified. Axis parallel
parallel and
quasi stat
quasi static
ic
errors quasi static
e rrors Z
FProcess angularerror
angular error
X, 
X, Y,ZZ
Y, X X
A B
A BC
C
2 Mode of operation of the compensation modules Y

Detection of demanded / actual error at the TCP

The development of adaptronical compensation modules is
focused on structure components of machine tools, which
have distinct weak spots concerning the occurring structure
deformations. Only at such components can an optimal
effectiveness of the applied compensation modules be
expected. In addition to this, the limited forces of the used
actuators can be utilized effectively at these weak com-
ponents. The exact placement and arrangement of the
compensation modules is determined based on a finite-
element analysis of the structure mechanical behavior of
the considered machine tool. The weak spot analysis is
done with the help of coupled flexible multi body models.
In doing so, the static and dynamic behavior can be
determined accurately while considering the structure
mechanic and feed drive influences.
In addition to the determination of the best possible
placement of the actuators, the effectiveness of the com-
pensation is defined to a great extent by the selected
compensation strategy. For the developed approaches, the
strategy applied is described below.
The occurring deformations on the TCP are compen-
sated by different means. The quasi static axis-parallel
deformations caused by static loads or temperature effects
are compensated by the feed drive offset- intrusion. The
axis-parallel dynamic deformations and angular deforma-
tions at the TCP will be balanced with the help of the
compensation modules. The principal approach of the
described compensation strategy is depicted in Fig. 1. The
detailed determination of optimal force transmission
points, as well as the effective direction and the amount of
the required compensation forces, will be described in the
following chapters.
TCP
de tection with adaptronic modules
- detection
- indirect detection with auxiliary-quantities
Functionality of compensation modules
Fig.
1
machine were set up and verified by metrological investi-
gations of these machines. The stiffness and damping
parameters of machine elements, such as guide ways and
bearings, were verified based on metrological investiga-
tions until a good correlation between the results of the
metrological investigation and results of the simulation was
assured.
The weak spot analysis was conducted with a finite-
element-analysis (FEA). Figure 2 shows the results of the
weak spot analysis for all three modeled machine types.
According to Fig. 2, the box-in-box-machine and the col-
umn machine have a relatively well-balanced deformation
behavior. The occurring deformations on all structure parts,
compared to the total deformation at the TCP, are between
14 and 27%. Thus, the compensation of structural defor-
mations with the help of adaptronical compensation
modules on machines with such balanced deformation
behavior is relatively ineffective.
However, on long projecting structure components, such
as the z-slider of a portal machine, large deformations in
excess of 40% of the total deformation at TCP occur. These
structural components represent a distinct weak spot in this
machine concept and are well suited for an effective
application of the adaptronic compensation modules.
Therefore, the further analysis for the development of the
compensation modules are confined on slider structures
that are deployed in portal lathes and milling machines in
vertical design and in boring machines in horizontal design.

3 Simulation of different machine tools and

weak spot analysis
As a basis for the development of adaptronical compen-
sation modules, the structural mechanic behaviors of three
standard types of machine tools were analyzed and their
weak spots were evaluated. In detail, simulation models of
a column machine, a box-in-box machine, and a portal
4 Analysis of the configuration of the
compensation forces
The analysis of the effectiveness of different adaptronical
compensation modules in relation to their placement as
well as the force generation is significant for the efficiency
of the compensation. The use of simulation models offers

13
Prod. Eng. Res. Devel. (2008) 2:219–223 221

Column Machine
Column z case 1 case 2 case 3 case 4
x
Load case Fx Deformation rates x y Fk
4% 6% 7% 300
7% 1 Fk Fk
6
8 3 4 27%
5
2 7
Fk
22%
8%
19% Fk
1 Base 4 Fixture 7 Slide
Fs Fs Fs Fs
2 Column 5 Headstock 8 Guideways
Guideways
3 Drives 6 Main spindle case 5 case 6 case 7 case 8

Box-in-Box-Machine
Box-in-Box-Machine Fk
Fk Fk
Load case F x Deformation rates x
11% 11% Fs Fk
6%
3 6 1 stiffness
8 4 14% kyy= 27 N/µm
5 7
2 sheet thickness
16% = 14 mm
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
Guideways
Fig. 3 Compensation forces on a z-slider
3 Drives 6 Main spindle

Portal Machine
The analysis of the configuration of the reset forces on
Load case F x Deformation rates x
the above depicted z-slider structure shows that the actu-
6% 10% 8%
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%
41% in an axis. In comparison to the other configuration cases,
8%

1 Base 4 Z-Slider 7 Cross

the transmission factor Ü between the process force FS and
1 Base
2 Cross slider
2 Cross slider
4 Z-Slider
5 Guideways
7 Cross
-beam
-beam
5 Guideways 8 Drives
the required compensation force FK is, in this case, at its
3 B-Axis
3 6 Main spindle 8 Drives lowest. Figure 4 shows exemplarily for the case 8 the
B-Axis 6 Main spindle

required force conditions for a complete axis parallel

Fig. 2 Weak spot analysis on simulation models
an effective way to determine the optimal placement of the
compensation modules in a machine structure. In order to
evaluate the effectiveness of different compensation strat-
egies, different calculations were conducted with a finite-
element-model of a slider structure that complies in its
dimensions and properties with a z-slider of a gantry-
machining centre. The different configurations of the
compensation forces for this analysis are shown in Fig. 3.
The TCP of the slider model was loaded with a force of
Fs = 500 N for this analysis, since the developed append-
ages are of special relevance for high precision finishing
operations. The accuracy and surface quality for rough
machining processes are rather circumstantial.
The occurring deformations due to the process force on
the TCP were compensated with varying compensation
forces FK on the simulation model. The aim was to deter-
mine the transmission ratio Ü between the process or
disturbing force FS and the compensation force FK for
different configurations and placements of the compensa-
tion forces. By doing so, the best possible configuration and
combination of compensation forces as well as the amount
of the compensation forces dependent on arrangement and
orientation of the compensation modules were determined.
compensation, as well as an angular compensation at the
TCP.
As shown in Fig. 4, actuators have to apply nine times
the process force (applied at the TCP) in order to com-
pletely compensate the occurring axis parallel
deformations. The force transmission factor Ü for a com-
plete angular deformation compensation amounts to 6.3.
Besides the technological properties of the selected
actuator principal, the integrability into a machine tool as
well as the economic efficiency is an important assessment
criterion for the industrial usage of such active compen-
sation systems. Based on the above mentioned analysis and
assessment criteria, a detailed characterization of different
actuator types with regard to their applicability in the
compensation modules was conducted. The technological
criteria considered were the actuator forces, the stroke and
the frequency range, wherein the actuators should apply the
required forces. Due to the sensory properties, which allow
the actuator to also be used as a sensor, and considering the
higher dynamic actuating forces, piezo elements were
selected as actuators for the compensation modules. The
effective integration of actuator or measurement systems
near the TCP is often very challenging. The compact size
of piezo actuators eases the integration of the compensation
systems into machine tool structures. The demands con-
cerning compensation forces, stroke as well as low reaction

13
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

Metzele [5, 6] in order to consider the nonlinear behavior

load Fs at TCP

of piezo actuators for the subsequent sensor modeling. A

+ control block with proportional controller was built up in
MATLAB/Simulink1 for the control of the piezo actuator.
In order to verify the operability of the adaptronical com-
pensation modules in the described simulation
z environment, coupled simulations were conducted on the z-
x slider structure (actuator configuration according to case 8
y Fs in Fig. 3).
= The structure of the model in the multi body simulation
environment and the coupling procedure are shown in
Translative compensation Ü = 9
Resulting deformation at

Fig. 5. The multi body simulation model considers the

Detail x
flexible model of the z-slider, the mechanical components
Rest
of the actuators, as well as the connection between the
compensation modules, and the z-slider structure. At the
TCP

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
l Rest and a proportional controller.
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

Fig. 5 Coupled simulation z-slider structure in CACE Simulation environment Matlab/Simulink®

multi body simulation interface
Control block
Compensation modules

at TCP

Compensation
forces

Linear piezo
actuator model
Process forces
TCP Excitation at the TCP

13
Prod. Eng. Res. Devel. (2008) 2:219–223 223

2,0E-5
6 Conclusion and outlook
1,87E-5
This paper presents the development of adaptronical
compensation modules to compensate static and dynamic
Inclination on TCP [rad]

deformations of structure components of machine tools.

1,0E-5 First, the basic feasibility of the compensation strategy with
Inclination on the
the TCP
TCPwithout
without
compensation at 500 N load
load
the structure integrated adaptronical compensation mod-
ules was the focal point of the study. With the help of
simulation tools, a detailed analysis concerning the
mechanical efficiency of the compensation modules as well
0,0 as a systematic assortment of actuators was done. The
Inclination on the TCP with
Compensation at 500
500 N
Nload
load
efficiency of the adaptronical compensation modules could
be proven on the coupled model of a z-slider structure.
0,0 0,5 1,5 2,0
Time [sec] Future research will be centered on the development of a
model based sensor-less control for piezo actuators. Using
the sensory properties of the piezo actuators, additional
Piezo actuator force displacement sensors at the TCP can be omitted. The dis-
3250
3000 placements at the TCP can be detected indirectly by
detecting the forces on structure integrated piezo actuators.
Force [N]

The implementation and analysis of compensation modules

2000
1000
Load at the TCP: 500N
0,0 0,5
Time [sec]
Fig. 6 Results of the coupled simulation
without compensation. The simulated process force on the
TCP and the required compensation forces, which are
applied by the piezo actuators, are shown on the second
graph in the figure. The occurring inclination on the TCP is
completely compensated with the help of the compensation
modules.
The applied forces of the compensation modules are
nearly identical with the finite element calculation of the
configuration forces (see Fig. 4). The overshoot behavior at
the TCP can be traced back to the resonance frequency of
the z-slider. The possibilities for compensation of such
dynamic deformations will be analyzed in the context of
sophisticated control strategies.
The described analysis shows that in sufficiently com-
pliant structure components of a machine tool, reverse
deformation can be induced by applying compensation
forces in order to compensate the occurring deformations
caused by process loads. After the feasibility of the adap-
tronical compensation modules was verified with the help
of a simple proportional controller in the current project
phase, the control block will be enhanced with more
effective control strategies.
with the entire control in a complete machine model will be
an additional task. Furthermore, a demonstrator will be
designed in order to verify the capability of the compen-
sation systems in practical tests.
The objective is to develop effective compensation
possibilities with robust control strategies for practical
1,5 2,0
applications in metal cutting machine tools and to verify
them with real machine components. If the strategy suc-
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
fulfillment of the demands concerning, on one hand, high
velocities, accelerations, and resulting higher jerk values
with lower masses of the components, and on the other
hand, higher static and dynamic stiffness of the structure
components.
References
1. Weck M, Brecher C, Giesler M (2002) Effiziente Entwicklung von
Werkzeugmaschinen- mit virtuellen Prototypen direkt zum markt-
fähigen Produkt, Tagungsband Aachener Werkzeugmaschinen
Kolloquium 02, Shaker-Verlag, Aachen
2. Ehmann C, Schönhof U, Nordmann R (2001) Aktive
Schwingungsdämpfung bei Portalfräsmaschinen, VDI-Berichte
Nr. 1606, pp 163–181
3. Michels F (1999) Stabilisierung des Schleifprozesses mit aktiven
Systemen, Dissertation, RWTH Aachen
4. Döngi F (1998) Adaptive Structures in High Precision Satellites,
Fortschritt-Berichte VDI Reihe 11, Nr. 268, Dü sseldorf, VDI-
Verlag, pp 429–438
5. Schugt M (2002) Aktor-Sensorverhalten von Piezoelementen in
Kfz-Diesel-Einspritzsystemen, Dissertation, university Bochum
6. Metzele M (2004) Piezoaktoren regeln die Lagervorspannung, wt
Werkstattstechnik Online, 94 Nr. 7/8, pp 344–349

13