INTRODUCTION The beds, columns, bases and housing are together called the structure of a machine tool It also form the backbone of the machine tools
The weight of the structure is around three
fourth of the weight of a machine tool In modern machine tools the structure is normally lighter. The structure transmits the static load (due to various parts such as the headstock) and the operational load (caused by the cutting force and by power transmission) to the support. CLASSIFICATION According to the purpose: Bed. frame works etc. Bases, bed plates Housing, boxes, columns etc. Casing and covers. According to the method of manufacture: Cast Welded Partly cast, partly welded. Accordance with the pattern of the transmission of the operational loads: Closed Open structure REQUIREMENTS OF A MACHINE TOOL STRUCTURE The suitability of a machine tool structure is judged from the following standpoints: sufficiently high strength (high static and dynamic rigidity) The shape and layout of the machine tool should facilitate easy chip removal, easy machining operation (with least possible fatigue of the operator and his permit easy and safe observation of the cutting operation, permit easy assembly and dismantling of parts and allow easy accessibility and maintenance of the machine tool. cost considerations, easiness in installation and transportation and aesthetic appeal. STRENGTH, STATIC AND DYNAMIC RIGIDITY The forces and the torque are caused by the cutting forces, the drive elements (such as belts, gears etc ) and the reactions in the bearings For machine parts running at high speeds the dynamic load, causing forced self exited or/and parametric vibrations, is also important In the case of resonance vibrations, the magnitude of stress is very high. The actual stress is kept low with the help of various re-enforcing stiffeners STRENGTH, STATIC AND DYNAMIC RIGIDITY It was earlier thought that heavy (machine tool) structure is necessary to dampen the vibration Experiments that structure should rather be light and rigid Consequently, the modern machine tools structure are more and more made of welded sheet structure and have suitably arranged ribs Hence the different pans of a machine tool structure do not always have uniform cross-section Apertures or holes are brought in the structure, for example for easy removal of chips, easy assembly and dismantling of the machine tools The apertures decrease the rigidity, specially the torsional rigidity to a grant extent. STRENGTH, STATIC AND DYNAMIC RIGIDITY
Fig. Torsional deflection of box-type beams with an
aperture in one side (Bielefeld) STRENGTH, STATIC AND DYNAMIC RIGIDITY The reduction of rigidity caused by the apertures can be to a large extent neutralized through suitable arrangement of stiffeners The straight traverse stiffeners increase the torsional rigidity by 34%, but its effectiveness (rigidity to weight ratio) does not increase Investigation of V. Kaminskaya and D.N. Reschtow on lathe beds have shown that the bed height should be approximately equal to bed width, which has the biggest influence on the rigidity of the bed STRENGTH, STATIC AND DYNAMIC RIGIDITY MATERIALS OF THE STRUCTURAL COMPONENTS
Cast iron is most widely used as structural
material Modern machine tools are also made of steel
Both the materials have economic and
technological advantages and disadvantages Researchers have shown that materials like ceramics, different types of concrete, granite can be good materials as well Their comparative advantages depend on: material properties and its availability manufacturing process and cost economy. MATERIALS OF THE STRUCTURAL COMPONENTS The selection of a certain particular material for the construction of machine tool structures is based on the following factors: high static stiffness (deformation against bending and torsion), good dynamic rigidity (obtained through high natural frequency and high damping ratio), good machinability, low coefficient of thermal expansion, dimensional stability during the life of the machine tool (specially resistance to wear), reduced weight (for easiness to transport) easy availability sliding properties (low friction and no stick-slip effect) and low cost in lot production. MANUFACTURING PROCESSES While manufacturing machine tool structures with a given material, it should be kept in mind to construct the same with least material Points to be kept in mind are: while manufacturing the structure the minimum wall thickness required must be maintained in casting sharp change-over of cross-section may cause casting faults Ordinary sand casting needs more machining allowance Internal stresses are to be remove as for as possible Production facilities and manpower DIFFERENT MATERIALS USED Different materials are used for manufacturing of machine components. Study advantages, disadvantages and application of each of the following materials: Cast Iron (Cl) Steel Ceramics Concrete Epoxy Concrete Polymer-impregnated Concrete (PIC) Ferro-Cement Fiber Reinforced Cemented Composites EFFECT OF CHIPS ON THE DESIGN OF THE STRUCTURE Modern machine tools are designed to remove material at a high rate which has two distinct consequences: it results in a very high volume of chip formation chip acts as a source of heat. Thermal expansion of the machine structure causes the development of internal stress It also causes loss of dimensional accuracy This is avoided by incorporating modification in the design of the machine tool structure and by the use of mechanized chip (material) handling equipments. The space between the stiffeners (webs) can be sufficiently large to facilitate free falling of the chips. It can be further improved if the bed is inclined. The quick removal of large volume of chips is attained by screw or belt conveyors INSTALLATION OF MACHINE TOOL The installation of machine tools also influences the design of machine tool structure Machine tool, being a source of chatter and other vibrations, may cause vibration of other equipments and machines In earlier days, a heavy mass was bolted to the structure to reduce resonance frequency This method has two main problems: Cost involved in the foundation Reduced flexibility in factory layout However, machine tools are nowadays more slick less weight and are placed on spring with dampers. These dampers also reduces outside vibration (Passive isolation) INSTALLATION OF MACHINE TOOL
Fig.: Machine tool structure bolted to the foundation