Наука и техника (May 2015)
MODELING AND ANALYSIS OF DYNAMICS IN BEARING SYSTEM OF DRILLING, MILLING AND BORING MACHINE WITH MONO-COLUMN
Abstract
FEM-analysis of dynamics in the bearing system of a heavy-duty machine tool has been carried out in the paper. This is a prospective variant for a large-size multi-purpose machine tool with a horizontal sliding ram. A saddle and a ram are moving vertically along a subtle mono-column. A rigid double-column is used in the existing analog machine tool. A static, modal and harmonic analysis of the bearing system with the mono-column has been made in the paper. It has been done with the help of FEM-simulation prior to fabrication of a prototype sample. Previously conducted calculations for the analog machine tool have shown good compatibility of FEM-calculation with experiments.Six common machine tool resonances have been revealed for the bearing system. Their oscillating cutting forces are actively exciting three-four resonance modes. Ranges of a flexure-torsion resonance (20–40 Hz) and nose-diving resonances (70–90 Hz) have been determined in the paper. The paper shows that the range of multi-wave resonances starts significantly higher from 140 Hz. These resonances are interconnected with bending oscillations of the ram and bucklings of the column walls which are matched with the oscillations. The paper demonstrates stability in resonance pattern. The torsional resonance of the column on the frequency of nearly 40 Hz is considered as the more dangerous one. Spindle rigidity goes down up to 3.8 Н/μm. It is possible to observe self-stabilization of the torsional resonance. Frequency of the torsional oscillations is practically unchangeable when there is a lifting or lowering down of the saddle and the ram. It is related to the migration of dynamical axis of torsion.Frequency-response characteristics of the bearing system have been constructed for various saddle positions on the column. Three frequency intervals that make it possible to carry out machining operation have been determined in the paper. The first interval is a static one. The machine tool with a mono-column comes short of the analog machine tool in this interval. The main reason of it is low static rigidity of the subtle column. The second interval is narrow and it is located between flexure-torsion and nose-diving resonances. The third interval is considered as the most efficient one. The interval contains a section of inter-range pause between general machine tool and multi-wave resonances. In this case it is possible to observe a significant increase of the dynamic rigidity on the spindle that compensates the column subtility. High potential of the dynamic rigidity has been revealed in the direction of the ram axis (>2000 Н/μm). The paper shows liability of the machine tool to displacement crossings during oscillations. Peculiar features of this effect have been discussed in the paper. The diagram with a mono-column is recommended for practical application. The main condition is a transition to high-speed drive within the framework of concept on high-speed machining. It is necessary to ensure rigidity of the axial feed drive system.
