Week 6 Components of Machine Tool

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INTRODUCTION TO MECHANICAL MICRO MACHINING

Machine tool components
PT
Ajay M. Sidpara
NMechanical Engineering Department

IIT KHARAGPUR
1
Structural configurations of a machine tool
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PT
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www.micromanufacturing.com
Ajay Sidpara
Mechanical Engineering
IIT KHARAGPUR 2
Structural configurations of a machine tool
The most popular vertical machine geometry: C‐frame construction (vertical
machining centre).
Spindle or Z‐axis is the only moving axis and table motion for all other axis
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travels
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• High stiffness  high accuracy
Stiffness decreases with the length of Z‐travel.
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Balance between tight tolerance and the length of Z‐travel.
Capitalizing on the Growing Demand for Micro‐Milling - A Mold Maker’s Guide || www.micromanufacturing.com || Luo et al. (2005) https://doi.org/10.1016/j.jmatprotec.2005.05.050
Ajay Sidpara
IIT KHARAGPUR 3
Structural loop
How efficiently and accurately can you cut ??
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PT
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Ajay Sidpara
IIT KHARAGPUR 4
Structural loop in machine
It contains all the joints and structural elements that position the tool w.r.t. the
workpiece.
The structural loop
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gives an indication of
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machine stiffness
and accuracy.
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Prof. Alexander Slocum (http://kinematiccouplings.org/)
Ajay Sidpara
IIT KHARAGPUR 5
Open loop structure
Lack of symmetry
Long open loops have less stiffness and less
accuracy
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Good for small, low-load machines
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Ajay Sidpara
IIT KHARAGPUR 6
Closed loop structure
Easy access to work zone
Strong ridged structural loop
Good thermal stability
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Used in macro-scale ultra-precision
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machines like CMMs
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Ajay Sidpara
IIT KHARAGPUR 7
Parameters affecting structural loop
Unknown or un-controllable changes in the structural loop are the primary source
of kinematic errors in machining.
Each change tends to
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maximize the error
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between the workpiece and
tool edge.
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Dr. Friedrich (MTU) http://pages.mtu.edu/~microweb/chap2/ch2-3.htm (NSF funded)
Ajay Sidpara
IIT KHARAGPUR 8
Errors in machining
There is no such thing as the perfect part.
An error  Any influence which deviates machined part from the "perfect" part.
Criteria for acceptable parts:
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• Tolerances are within some acceptable range
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• Roughness which does not exceed some allowable limit set by the application
• A shape which satisfies the application
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• A material with properties which are at least predictable within some range of
uncertainty.
Ajay Sidpara
IIT KHARAGPUR 9
Cost vs. Performance in error correction
How much time/money spent to look for the sources of errors to prevent or
minimize the errors.
Successful projects keep a close watch on budgets (time, money, performance)
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Understanding errors in components
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and machines is the key to staying on
the leading edge.
“Bleeding edge” designs can drain you. N
Prof. Alexander Slocum (http://kinematiccouplings.org/) || Precision Manufacturing by Dornfeld and Lee, Springer, 2008
Ajay Sidpara
IIT KHARAGPUR 10
Sensitive directions
We have to ask ourselves, “when is an error really important?”
Put a lot of effort into accuracy for the directions in which you need it
• The Sensitive Directions
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• Always think about where you
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need precision.
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Ajay Sidpara
IIT KHARAGPUR 11
Machining error generating process
Error source Mechanical system Error generating process Machining accuracy
Static deformation
Structure Contour
Geometrical Dynamic deformation accuracy
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Spindle
error Table Thermal deformation
Surface
Machine tool Rotation accuracy
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roughness
Cutting Guiding accuracy
Workpiece Dimensional
Drive Dynamic movement error
Environment
Tool
N Tool wear
accuracy
Precision Manufacturing by Dornfeld and Lee, Springer, 2008
Ajay Sidpara
IIT KHARAGPUR 12
Geometric Errors of Machines
Machine tools and measuring equipment with 3 to 5 axes are widely used in
fabrication and characterization of the component.
Accurate parts can only be achieved
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by a controlled and deterministic
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manufacturing process.
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http://www.etalon-ag.com/en/technology/geometric-errors-of-machines/
Xiang et al. (2015) Proc IMechE Part B
Ajay Sidpara
IIT KHARAGPUR 13
Geometric Errors of Machines
Geometric accuracy of the part can be
achieved either by
• a feedback loop through part
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metrology or
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• accurately calibrated machine tools.
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http://www.etalon-ag.com/en/technology/geometric-errors-of-machines/ || Precision Manufacturing by Dornfeld and Lee, Springer, 2008
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IIT KHARAGPUR 14
Sources of geometry errors
Accuracy of machine tool is affected by many error sources.
Kinematic Thermo-
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errors mechanical errors
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Dynamics
Loads
forces
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http://www.etalon-ag.com/en/technology/geometric-errors-of-machines/ || Hernández–Martínez et al. Ing. invest. y tecnol. vol.11 no.2 México abr./jun. 2010
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IIT KHARAGPUR 15
Kinematic errors
Due to imperfect geometry, alignment and dimensions of machine components.
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They are stable or changing slowly over time e.g.
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• due to foundation drifts,
• wear or material aging and
• also collisions. N
Ajay Sidpara
IIT KHARAGPUR 16
Thermo-mechanical errors
Internal and external heat sources in the machine may lead to thermo-mechanical
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deformation of machine components  leads to kinematic errors.
PT
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IIT KHARAGPUR 17
Loads
In some cases, the weight and position of a workpiece have a significant influence
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on the machine’s geometry.
PT
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Ajay Sidpara
IIT KHARAGPUR 18
Dynamics forces
Machining is affected by the dynamic stiffness of the machine’s structural loop.
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Varying forces such as machining forces or forces caused by accelerations /
decelerations are causing deformations.
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IIT KHARAGPUR 19
Kinematic structures of machines
It is defined by the layout of machine components and their axes.
Most machine tools have a serial structure: One axis of motion is on another.
A notation based on Schwerd for serial kinematic structure (Tool  Workpiece).
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PT
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Ajay Sidpara
IIT KHARAGPUR 20
Description of geometric errors
Errors of a machine tool are relative motions error between the tool and the
workpiece.
Each movement of a machine axis can be described by six degrees of freedom:
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three translations and three rotations.
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The notation of an axis movement is standardized in ISO 841:
Linear movements  X, Y, and Z
Rotational movements  A, B, and C N
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IIT KHARAGPUR 21
Flatness, Straightness, and Smoothness of Motion
Kinematic entities of machine are assumed to be perfect.
• Spindle  Single axis of rotation which coincides with the geometric axis of a
rotating joint.
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• Slides  They travels in a straight line with only one degree of freedom of rigid
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body motion (i.e. no tilting or swaying).
This of course is not true.
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Ajay Sidpara
IIT KHARAGPUR 22
Independent vs. coupled motion
A round object sliding within a bore  rotation and translation  2 DoF.
Bolt and nut  rotation and translation coupled  1 DoF
In machine tools  motions are assumed to
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be 1 DoF actions.
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Not true
Motions are coupled and this further leads
to machining errors. N
Ajay Sidpara
IIT KHARAGPUR 23
Flatness and straightness runout of a linear stage
Runout of a Linear Stage is the linear portion of off-axis error.
It consists of two orthogonal components.
Flatness
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It is a displacement error along the z-axis.
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Straightness
It is a displacement error along the y-axis
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https://www.newport.com/n/motion-basics-and-standards
Ajay Sidpara
IIT KHARAGPUR 24
Effect of flatness error on tool / workpiece location
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PT
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Dr. Friedrich (MTU) http://pages.mtu.edu/~microweb/chap2/ch2-4-5.htm (NSF funded)
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IIT KHARAGPUR 25
Roll, pitch and yaw angular runout of a linear stage
Angular runout is the angle measured between the actual motion and the ideal
straight line motion of a linear stage.
It has three orthogonal components 
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• Pitch
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• Roll
• Yaw
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https://www.newport.com/n/motion-basics-and-standards
Ajay Sidpara
IIT KHARAGPUR 26
Smoothness of motion
Smoothness is related to stick/slip behavior of stage bearings or drive mechanism.
Lack of smoothness of motion  Sudden jumps in the motion followed by a
period with no motion.
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Jump  Relatively high machining forces for a brief period and can lead to cutting
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tool failure.
Sudden jumps can also be a source of
vibration if the stage is heavy or is supporting
a massive workpiece or other structure.
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Ajay Sidpara
IIT KHARAGPUR 27
Axis orthogonality
Kinematic links ideally situated at right angles to each other.
It is assumed the right angles are present and are maintained throughout all
operational procedures.
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A motion of only the y-axis, which carries
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the x-axis stage, will result in some
amount of x motion due to the axes not
being at right angles. N
Ajay Sidpara
IIT KHARAGPUR 28
Orthogonal error in Z axis
A non-orthogonal z-axis motion
could result in motion components
in x and y if the non-orthogonality
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is two dimensional.
PT
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Ajay Sidpara
IIT KHARAGPUR 29
6 error components in a linear movement (x axis)
• 1 position error
• 2 straightness error motions
• 1 roll error motion and
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• 2 tilt error motions (pitch & yaw error)
PT
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Ajay Sidpara
IIT KHARAGPUR 30
6 error components in a rotational movement
• 2 radial error motions
• 1 axial error motion
• 1 angular position error
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• 2 tilt error motions
PT
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Ajay Sidpara
IIT KHARAGPUR 31

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EL

INTRODUCTION TO MECHANICAL MICRO MACHINING

NMechanical Engineering Department

• The Sensitive Directions

Precision Manufacturing by Dornfeld and Lee, Springer, 2008

Due to imperfect geometry, alignment and dimensions of machine components.

Machining is affected by the dynamic stiffness of the machine’s structural loop.

In machine tools  motions are assumed to

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