Investigation of machine tool rigidity through measurements and FEA

Official URL: http://risc01.sabanciuniv.edu/record=b1640316 (Table of Contents)

Machining is one of the most widely used methods in manufacturing among others and the progress of machining will continue to grow with the developing technology. In modern day, people seek for high quality and accurate products with less machining time. In order to fulfill these goals; rather than using old and traditional methods, using high speed machining processes, advanced equipment and well-trained staff are essential. Moreover, engineering software programs play a key role in the tracking and the analysis of the processes which enable the users to make the required modifications in a short time. It is possible to make simulations for different cases, models and designs without making any physical changes in the real system by means of these software programs. The main aim of this thesis is; to determine the weak components of machine tool spindles by analyzing and comparing different machine tools, to model the contact elements on the spindle analytically and to construct a model of the entire machine tool by using FEM. Static and dynamic analysis on different machine tool spindles are conducted and by comparing the results, weak components of the spindle are determined. Connection components on the machine tool spindle are analytically modeled and the results of this model are compared with the tests applied on the connection components. FEM model of the entire machine tool is constructed and results of the conducted tests are compared by applying deformation analysis to this model. Several suggestions to increase the rigidity of the machine tool are made by using the verified model. At the end of the study, overall good agreement is observed between the experiments, simulations and the models.