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• Lit. Review Lite 2: Frame Design Continued

  Albert Latham • 08/16/2015 at 19:21 • 0 comments

  My light literature review continues. In this rather short episode I consider more advanced math that I am rather unprepared to tackle. Huzzah for brain-pain!

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  Park, Sung-Ryung, and Seung-Han Yang. 2010. “Design of a 5-Axis Machine Tool Considering Geometric Errors.” International Journal of Modern Physics B 24 (15n16): 2484–89. doi:10.1142/S0217979210065131.

  Overview

  This paper presents a kinematics drive approach for modeling and predicting volumetric error within a 5-axis mill's movement. Three mill configurations are considered, analyzed, and the critical design factors contributing to volumetric error are identified.

  How is this study useful to this project?

  This study may represent a way to identify components and assemblies that are critical to precision very early in the design phase. Further, because the math is available it may prove useful during computer driven design revisions for the identification and selection of components that minimize volumetric errors.

  What problems will utilizing this research present?

  Aside from my distinct lack of training in mathematics the largest challenge will be to appropriately integrate this into some form of computer driven task. A deeper understanding of the method and its outcomes will aid in figuring out where this will fit in the design process and what decisions it will contribute to making.
  

• Lit. Review Lite: Frame Design

  Albert Latham • 08/16/2015 at 01:28 • 0 comments

  This is a lighter literature review than some applications call for. I am excusing myself from anything more deptailed until I understand the math behind most Mechanical Engineering. Currently I lack a background in Physics, Statics, Dynamics, Calculus (differential and partial differential equations), Linear Algebra, and applications there-of.

  I am taking steps to rectify these gaps in my knowledge. I have enrolled in a Calculus course at my local community college. I am enrolled in an online course for Linear Algebra and its applications (specifically in programming). I am completing a course in programming (CS50 through edX.org) after which I will be approaching Physics.

  And there is probably more that I haven't mentioned. Keeping all this straight is a task unto itself and it can be rather time-consuming.

  Complaining aside; here is what you've skipped everything above for:

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  Hung, Jui Pin, Yuan Lung Lai, Tzuo Liang Luo, and Hsin Chuan Su. 2013. “Analysis of the Machining Stability of a Milling Machine Considering the Effect of Machine Frame Structure and Spindle Bearings: Experimental and Finite Element Approaches.” International Journal of Advanced Manufacturing Technology 68 (9-12): 2393–2405. doi:10.1007/s00170-013-4848-6.

  Overview

  Analysis of the Machining Stability of a Milling Machine Considering the Effect of Machine Frame Structure and Spindle Bearings: Experimental and Finite Element Approaches (hereafter "the study" or "the paper") specifically considers the combined dynamics of a vertical milling machine frame and spindle. An application of finite element analysis was used to predict the dynamics of the milling machine and spindle and an experiment was used to confirm the analysis.

  How is the study useful to this project?

  In the introduction the author's clearly state how this application of experimental and mathematical analysis could be directly useful to an end-user, saying that, "The prediction [...] of the abnormal vibration is of great importance for the selection of the free chatter machining conditions." This study aims to specifically address the dynamic conditions that result from using a high-speed spindle in combination with the mill's frame. A complete solid model is used for the analysis, rather than a simplified model (as other studies have done).

  Items that are specifically useful are the mathematics and derived equations, the mathematic modeling methodology used for the spindle unit and mill unit.

  The math presented will allow me to not have to experiment to find the modal frequency by experimentation and will thus allow a program to handle the heavy lifting (iterative design via algorithm) once the design phase has begun.

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  1. Huo, Dehong, Kai Cheng, and Frank Wardle. 2010a. “Design of a Five-Axis Ultra-Precision Micro-Milling Machine-UltraMill. Part 1: Holistic Design Approach, Design Considerations and Specifications.” International Journal of Advanced Manufacturing Technology 47 (9-12): 867–77. doi:10.1007/s00170-009-2128-2.
  2. ———. 2010b. “Design of a Five-Axis Ultra-Precision Micro-Milling Machine-UltraMill. Part 2: Integrated Dynamic Modelling, Design Optimisation and Analysis.” International Journal of Advanced Manufacturing Technology 47 (9-12): 879–90. doi:10.1007/s00170-009-2129-1.

  Overview

  These studies walk through the design and implementation process of an ultra-precise ("nano-meter finish") 5-axis CNC milling machine. The first article focuses on the existing ultra-precision machines, component options, and the specifications for the proposed "UltraMill".

  The second article focuses on the modeling and simulation of the "UltraMill" with an emphasis on machine dynamics. The simulation allows the authors to predict the performance of the machine over its entire performance envelope.

  How is the study useful to this project?

  The second portion of the paper is far more useful than the first. While the first sheds some light on the goals of the entire project,...

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• Papers, Please.

  Albert Latham • 07/08/2015 at 21:21 • 0 comments

  I'm in the middle of a literature review in an effort to do two things. One, I'm looking to see what has been done before, and two, I'm attempting to sort out the math involved with designing machine tools well. Below I've the bibliographic entries for the papers I've pulled for review. I'll need to double or triple the number of papers before I will begin to understand the true nature of my undertaking.

  I'm currently working my way through the frame design portion of the list as it is the most pertinent to me right now. The results of my review will be used to select appropriate FEA and FEM software to begin design and analysis based on the design requirements.
  

  Frame Design

  • Bamberg, Eberhard, and Alexander H Slocum. 2000. “Principles of Rapid Machine Design.” Mechanical Engineering, 212.
  • Darvekar, Sanjay, a. B Koteswara Rao, S. Shankar Ganesh, and K. Ramji. 2013. “Optimal Design and Development of a 2-DOF PKM-Based Machine Tool.” International Journal of Advanced Manufacturing Technology 67 (5-8): 1609–21. doi:10.1007/s00170-012-4594-1.
  • Garro, O., and P. Martin. 1993. “Towards New Architectures of Machine Tools.” International Journal of Production Research. doi:10.1080/00207549308956865.
  • GARRO, O., P. MARTIN, and H. MARTI. 1992. “Algebraic Description for Machine Tool Design.” International Journal of Production Research. doi:10.1080/00207549208948179.
  • Hung, Jui Pin, Yuan Lung Lai, Tzuo Liang Luo, and Hsin Chuan Su. 2013. “Analysis of the Machining Stability of a Milling Machine Considering the Effect of Machine Frame Structure and Spindle Bearings: Experimental and Finite Element Approaches.” International Journal of Advanced Manufacturing Technology 68 (9-12): 2393–2405. doi:10.1007/s00170-013-4848-6.
  • Huo, Dehong, and Kai Cheng. 2008. “A Dynamics-Driven Approach to Precision Machines Design for Micro-Manufacturing and Its Implementation Perspectives.” doi:http://dx.doi.org/10.1016/B978-008045263-0/50007-6.
  • Huo, Dehong, Kai Cheng, and Frank Wardle. 2010a. “Design of a Five-Axis Ultra-Precision Micro-Milling Machine-UltraMill. Part 1: Holistic Design Approach, Design Considerations and Specifications.” International Journal of Advanced Manufacturing Technology 47 (9-12): 867–77. doi:10.1007/s00170-009-2128-2.
  • ———. 2010b. “Design of a Five-Axis Ultra-Precision Micro-Milling Machine-UltraMill. Part 2: Integrated Dynamic Modelling, Design Optimisation and Analysis.” International Journal of Advanced Manufacturing Technology 47 (9-12): 879–90. doi:10.1007/s00170-009-2129-1.
  • Kono, D, T Lorenzer, and S Weikert. 2010. “Comparison of Rigid Body Mechanics and Finite Element Method for Machine Tool Evaluation,” 1–26. doi:10.3929/ethz-a-006111492.
  • Li, Baotong, Jun Hong, and Zhifeng Liu. 2014. “Stiffness Design of Machine Tool Structures by a Biologically Inspired Topology Optimization Method.” International Journal of Machine Tools and Manufacture 84. Elsevier: 33–44. doi:10.1016/j.ijmachtools.2014.03.005.
  • Park, Sung-Ryung, and Seung-Han Yang. 2010. “Design of a 5-Axis Machine Tool Considering Geometric Errors.” International Journal of Modern Physics B 24 (15n16): 2484–89. doi:10.1142/S0217979210065131.
  • Zhang, Jianfu, Pingfa Feng, Chuang Chen, Dingwen Yu, and Zhijun Wu. 2013. “A Method for Thermal Performance Modeling and Simulation of Machine Tools.” The International Journal of Advanced Manufacturing Technology 68 (5-8): 1517–27. doi:10.1007/s00170-013-4939-4.

  Spindle Design

  • Liang, Yingchun, Wanqun Chen, Yazhou Sun, Nan Yu, Peng Zhang, and Haitao Liu. 2014. “An Expert System for Hydro/aero-Static Spindle Design Used in Ultra Precision Machine Tool.” Robotics and Computer-Integrated Manufacturing 30 (2). Elsevier: 107–13. doi:10.1016/j.rcim.2013.09.006.
  • Liu, Junfeng, and Xiaoan Chen. 2014. “Dynamic Design for Motorized Spindles Based on an Integrated Model.” International Journal of Advanced Manufacturing Technology, 1–14. doi:10.1007/s00170-014-5640-y.
  • Sabirov, Fan, D. Suslov, and Sergey Savinov. 2012. “Diagnostics of Spindle Unit, Model Design and Analysis.”...

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• Organization and Planning

  Albert Latham • 06/13/2015 at 21:27 • 0 comments

  I'm taking the time to properly organize and focus this project. This includes setting up project management through Asana, filling out the project files on Github, and calling for help. I'm trying to get this project done by the end of August (before I start into school again) and I don't think I'll make it by myself. There is plenty to do on this right at this moment and I'd love to start assigning tasks to people. Your level of knowledge in machine design doesn't matter as long as you're willing to teach yourself what you need to know.

  If you think you might like to help, leave me a comment below.

  What I've done:

  • Organized project on Asana.
  • Filled in the Github repository with the project framework (folders, files, proposal and project overview, etc.)
  • Called for help right here.

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