Advanced Materials Research Vol.

1037 (2014) pp 41-44 Submitted: 2014-06-11

© (2014) Trans Tech Publications, Switzerland Accepted: 2014-08-07
doi:10.4028/www.scientific.net/AMR.1037.41 Online: 2014-10-27

Characteristic Analysis and Optimization for The Tailstock Body of The

NC Lathe

LU Mo-Wu, Li Ming-Jie
JIANGSU,HUBEI,CHINA
570454645@qq.com,lumowu@126.com

Keywords: tailstock body; statics analysis; modal analysis; topology optimization; Workbench;

Abstract. The characteristics of the NC Lathe tailstock has great influence on the machining accuracy
of NC machine tools. Solidworks software is used to establish the tailstock body entity model, then
import it into the Workbench software for finite element analysis and conclude its dynamic and statics
characteristics. According to the result of the analysis on the topology optimization. Guarantee after
optimization, the tailstock body not only can satisfy the requirement of machine tool, the quality can
also be reduced by 5%. In saving material at the same time also can reduce the motion inertia, improve
the machining accuracy.

INTRODUCTION
The tailstock is an important part of the CNC lathe, it plays a role in positioning and clamping
workpiece. It's static and dynamic characteristics have a direct impact on the machining accuracy and
stability. When heavy duty NC lathe machining different parts, tailstock need reciprocating
movement to complete the task of clamping, positioning workpiece. So this requires the tailstock
weight is lighter, increase the flexibility of the organization as far as possible. In this paper, HTC100
CNC lathe tailstock box as an example, by establishing an accurate physical model, using ANSYS
Workbench software to finish finite element analysis and its topology optimization then obtain a
better structure. Provide a feasible reference for the reasonable design of the tailstock body.

FINITE ELEMENT MODEL

Figure 1 (a) is about HTC100 CNC lathe tailstock body structure, it assembly formed by the upper
and lower cabinet as FIG 1 (b), (c) shown in. The bottom of tailstock is fixed on the bed through the
slide rail and bolt.

Figure 1 (a) the tailstock box model (b) the upper box model (c) the lower box model
HTC100 horizontal CNC lathe tailstock is casted by the HT300. The modulus of HT300 is
1.43E11Pa, Poisson ratio is 0.27 and density is 7340Kg/m3.
Meshing is an important part of the finite element analysis. This paper chooses Patch in
Conforming method which belongs to the Tetrahedrons method to mesh the tailstock box model. The
reasons why this method is selected are that it is fast and applicable to the complex geometry;

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42 Development of Applied Engineering Sciences

Approximate size in the key areas can be refined. The finite element model is obtained after mesh is
shown in Figure 2, The number of nodes model is 55973 and the total number of unit is 32024.

Figure 2 The finite element model of box. Figure 3 The boundary conditions of box

It must be applied boundary conditions on the box in the ANSYS before analyzing statics and
dynamics of the tailstock box, including the force, torque and support surface. The tailstock body
internal stress mainly comes from gravity of parts. Besides the gravity of the internal parts, the
tailstock box is also got the cutting force and moment during the machining process.
Taking the shaft machining as an example, According to the empirical data, the tailstock clamping
force is 5.28KN, the maximum cutting force is 60KN. The main cutting force is 53.4KN, back force is
18.6KN and feeding force is 20.4KN. After stress analysis, the force and torque come from tip is got
as follows: Fx =560N, Fy =1572350N, Fz =15120N, M =8811N.m. Apply these forces and moments
to each surface of box, The tailstock body fixed on the bed, so the bottom of the box body is got by
fixed constraint. Boundary conditions are applied in the Workbench as shown in Figure 3.

FINITE ELEMENT ANALYSIS

The result of the static analysis has an important reference value to optimize the structure of the
box body. Analysis of static images as shown in Figure 4, the maximum displacement of the box body
is 1.23E-004m, the maximum stress is 4.44E+007Pa. The results show that the maximum
displacement of box is small, it can satisfy the precision demand. The ultimate stress of HT300 is
300MPa. The maximum stress of tailstock box is far less than the limited material stress, Box rigidity
meets the requirements, thus it may carry on further optimization.
During the process, machine tools generate periodic variational excited force by the interaction of
noise and vibration. It's easy to cause the resonance when the frequency of excited force is the same or
integer with the natural frequency of structure. It will reduce the machining precision and stability of
machine tool. So it is necessary to carry out the modal analysis of the tailstock box.

Figure 4 The displacement and stress nephogram of tailstock body

 Advanced Materials Research Vol. 1037 43

After modal analysis of box in the ANSYS, the first six-order modal is concluded as shown in table
I. The maximal speed of spindle of HTC100 CNC lathe is 200rpm and the frequency is 3.33Hz. It can
be seen that the excitation frequency of the tailstock is far less than itself first six-order frequency
from table 1.
Table 1. The low-order mode of box Unit[Hz]
Pattern 1-order 2-order 3-order 4-order 5-order 6-order
Frequency 272.27 283.95 462.53 636.54 747.78 806.67

TOPOLOGY OPTIMIZATION
Topology optimization is refers to find the best solution of structural materials used to make the
target volume (overall stiffness, natural frequency etc.) stable under given constraint condition. Using
"Shape Optimization" function in Workbench to finish the tailstock box topology optimization. The
optimization goal is set to 5 percent, then solve it, optimization results as shown in Figure 5.

Figure 5 The topology optimization nephogram Figure 6 The geometry structure after optimization
As the red resectable area is irregular, the complexity of technology and stress distribution must be
considered in the actual processing. So it is impossible to remove all red area. Cut off the red area in
regular geometry in Solidworks, then quality reduces 1250.4Kg. The geometric structure after
optimization as shown in Figure 6.
Make the finite element analysis on the optimization scheme and the displacement, stress
nephogram as shown in Figure 7. The maximum displacement of box is 1.19E-004m and the
maximum stress is 4.57E+007Pa after optimization. Modal analysis on the box body after structure
optimized is carried out and get the low order mode as shown in table 2.

Figure7 The displacement and the stress nephogram after optimization

Make statics and dynamics analysis on the optimized box structure, it can be seen the tailstock
body still meet the stiffness requirement and machining accuracy after optimization. Moreover, the
quality reduced, the movement inertia enclosure and the control performance improved.
44 Development of Applied Engineering Sciences

Table 2. The low-order mode of box after optimization Unit[Hz]

Pattern 1-order 2-order 3-order 4-order 5-order 6-order
Frequency 278.98 290.52 471.10 653.54 743.03 781.12

CONCLUSION
Doing topological optimization to the tailstock box in Workbench, the maximum displacement,
maximum stress and the low frequency basically unchanged after optimization design of the tailstock
box. It meets the design requirements and the quality is reduced by 5%.It makes the tailstock
movement more flexible.
Using finite element software to analyze the products can save the cost of manufacturing prototype
and testing. Getting the main properties of the product in the software, it could provide optimized
structure and size.

REFERENCES
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Development of Applied Engineering Sciences
10.4028/www.scientific.net/AMR.1037

Characteristic Analysis and Optimization for the Tailstock Body of the NC Lathe
10.4028/www.scientific.net/AMR.1037.41