A STUDY OF THE MODAL SHAPES OF MACHINE

TOOL COLUMN STRUCTURES

S. K. KARK, S. HINDUJA and A. COWLEY
Machine Tool Engineering Division, Mechanical Engineering
Department, UMIST, Manchester

SUMMARY
The paper describes the results obtained from finite element dynamic analyses of machine
tool column structures. Up to twenty modes of vibration have been examined. These modes in-
clude the fundamental and higher order bending and twisting modes as well as numerous panel
modes.
The finite element results are compared with experimental observations to demonstrate
the accuracy of the method of analysis. The computations are extended from the unribbed column
to other column configurations in order to study the influence of internal ribbing upon the various
modes of vibration. The types of ribbing examined include diagonal and diamond-shaped ribs and
horizontal partitions.

INTRODUCTION COMPUTED RESULTS FOR THE OPEN COLUMN

Column type structural elements are commonly
found in machine tool constructions. Their character-
istics in response to static and dynamic loading have
significant influence upon the relative movement bet-
ween the tool and the workpiece, and subsequently af-
fect machining performance and accuracy. Moreover,
their geometric shape is simple and regular; this ren-
ders them amenable to idealization using the finite
element method. For these reasons, column structures
have been chosen for investigation. The finite element
package used is that developed at UMIST [1,2]' The
dimensions of the column used in this investigation are
shown in Figure 1. This particular size and shape was
chosen because results of their static behaviour have
been reported [3,4] and the dynamic analyses reported
herein would give it a sense of continuity.
FINITE ELEMENT MESH CONFIGURATIONS
The open column shown in Figure 1 has been
analyzed using five different finite element meshes.
The meshes are designated as 1-1-3, 2-2-6, 3-3-9,
4-4-12 and 5-5-15. The three integers in each desig-
nation represent the number of sub divisions along the
X, Yand Z directions respectively. For example, the
mesh shown in Figure 1 is designated as 3-3-9. It has
a total of 108 nodes and 648 degrees of freedom (each
node had 6 degrees of freedom). With the node number-
ing shown in the figure, the nodal bandwidth is 14. The
size of each plate in all the five meshes has been main-
tained as square as possible.
The box column is treated as a thin-walled shell
structure made up of thin flat plates. Each plate has
in-plane and flexural properties and they are derived
from the four-term linear displacement function [ 5] and
the twelve-term non-conforming displacement function
[ 6 ] respecti vely. The inertia properties of each ele-
ment are based on a consistent mass matrix.
The free vibration modal shapes of the open
column may be classified into five different groups
according to their cross-sectional movements. They
are panel modes (PI and P2), bending mode (B),
pseudo-bending modes (Sl and S2), torsional distortion
mode (D), and a pure torsional mode (T) as shown in
Figure 2. Each of the shapes indicates the movement
of a particular cross -section. For each mode, the de-
formed cross-sectional shape is the same along the
length of the column but the amplitude of deformation
is different. Associated with each basic shape, there
are a number of modes distinguishable by the variation
in the amplitude along the length of the column as
shown in Figure 2(b).
The pseudo-bending modes Sl and S2 are con-
sidered as higher order bending modes because the
principal axis of the column deflects in accordance
with the higher bending modes associated with slender
beams. Alternatively, since there exists a consider-
able degree of panel deformation, the modes Sl and S2
may be classified as panel modes with the opposite
panels moving in the same direction.
The first five modes obtained with meshes
1-1-3 and 5-5-15 are shown in Figure 3 and 4 respec-
tively. Figure 5 shows the convergent curves for the
first five natural frequencies. Because of the sym-
metry of the column about the X and Yaxes, multiple
eigenvalues are obtained in the bending modes. The
curves converge quite rapidly and except for the fifth
natural frequency, the modes appear in the same se-
quence as the mesh is refined. Even mesh 1-1-3 with
nodes situated only at the corners gives vaguely recog-
nizable straight-sided modal shapes in correspondence
to those of mesh 5-5-15.
On examining the convergent curves, four con-
verge from above and one from below. This is not
surprising because the bending properties of each
plate have been derived from a non-conforming

213

S. A. Tobias (ed.), Proceedings of the Seventeenth International Machine Tool Design and Research Conference
© The Department of Mechanical Engineering, University of Birmingham 1977
214 MODAL SHAPES OF MACHINE TOOL COLUMN STRUCTURES
function and the results obtained with such a function
might either converge from above or below depending
upon the deformation pattern.
DYNAMIC BEHA VIOUR OF SOME RIBBED COLUMNS
Machine tool column structures must possess
the required static stiffness and dynamic rigidity to
withstand various static and dynamic loads. One com-
monly used method to ensure adequate rigidity is by
the use of internal ribbing arrangements which may
take a variety of forms. This will no doubt result in
higher static stiffness. However, such reinforcements
may not necessarily lead to a better dynamic perfor-
mance of the column. Extra ribs will inevitably add
to the total mass of the column and may result in a re-
duction of some natural frequencies. Correct position-
ing of ribs of appropriate configurations are important
factors to be considered. The following investigation
is an attempt to discover the possible effect of some
ribbing configurations on the dynamic behaviour of box
column structures.
Four alternative ribbing configurations have
been analyzed and the first twelve to twenty modes of
each are compared with those of the open column
(Figure 6). The four columns shown in Figure 7 were
discretised into mesh systems of nearly square rect-
angular elements of fineness comparable to mesh
3-3-9 used for the open column. The computed modal
shapes for the four ribbed columns are shown in
Figures 8,9,10 and 11. A study of the computed re-
sults reveals the following major observations:
(1) To compare alternative designs of a structure,
one can aclopt a simplified criterion that in
general a smaller number of modes within a
specified frequency range is likely to corres-
pond to improved dynamic behaviour. A close
examination of the distribution of the natural
frequencies of the different columns in the fre-
quency range of 0 to 1000 Hz shows that the
column with the diamond-shaped ribbing has
the most sparse distribution with only three of
its natural frequencies inside this range. The
column with horizontal partitions is also quite
satisfactory from the point of view that a large
gap exists between the first bending mode and
the first panel mode (PI), with the remaining
modes occurring at the upper end of the range.
The cross-rib configuration results only in a
marginal improvement. The diagonal rib, on
the other hand, has more modes than the open
column inside this frequency range.
(2) The majority of the modes of the open column,
for example, modes PI, P2, B, Sl and S2 in-
volve panel vibration. This indicates that the
fou:- mid-panel nodes are the weakest points in
any cross-section. Corner nodes are relative-
ly stiff as two plates meet at 900 and reinforce
one another. Hence ribbing support should be
so placed that the unsupported area of a panel
is reduced as far as possible. The diamond-
shaped ribs reduce the unsupported width of the
four panels by half and as a result of this most
of the panel modes of the main column are sup-
pressed. The diagonal and cross ribs reinforce
only the corners and hence have very little ef-
fect on panel vibrations.
(3) New modes are introduced by the ribs. For
example, the slender diagonal rib is respon-
sible for at least three new modes (Nos. 1, 2
and 5 in Figure 8) inside the frequency range.
Out of the twelve modes of the column with the
diamond- shaped ribs shown in Figure 11, only
four have correspondence with those of the open
column and the remaining eight involve panel
vibrations of the inner column. The column
with horizontal partitions does not introduce
new modes in the range as far as the cross-
sectional modal shapes are concerned, but the
wa viness along the length of the column is dif-
ferent because of the extremely small in-plane
movements in the planes containing the horizon-
tal partitions.
(4) Table I lists the natural frequencies of the open
column and the four ribbed columns. The fol-
lowing observations can be made:
(a) The inclusion of ribbing increases the natural
frequencies of all the panel modes (P). The
increase is relatively large in the case of
columns with diamond ribs and horizontal
partitions.
(b) The distortion mode (D) disappears from
within the range for all the four ribbing con-
figurations. This is because they offer con-
siderable resistance to cross-sectional dis-
tortion.
(c) The diagonal, cross-ribs and horizontal par-
titions increase the pure torsional stiffness of
the column only marginally and hence the
natural frequency of the torsional mode (T) de-
creases. In the case of the diamond-shaped
ribs, the increase in the torsional stiffness is
greater than the increase in mass and hence
torsional mode appears at a higher natural
frequency.
Another possible criterion for improvement is
to compare the modal flexibilities. The modal flexi-
bility of a particular mode is given by
{x.} {x.l T
I I
2
w.
I
where T{xJ is the orthonormalized modal shape such
that lx\ I[M 1 {xJ = l. It can be used as an indicator
of the ~ontribution land influence of the mode to the total
amplitude of vibration at any frequency. Instead of look-
ing at the modal flexibility of the whole column struc-
ture with both direct and cross flexibilities in an n x n
matrix [F.] (where n is the total degrees of freedom
possesseJby the structure), only the direct flexibilities
at nodes 1,2 and 14 (see Figure 1) have been computed.
The direct flexibilities in three major modes - the first
panel modes (PI), the first bending mode (B), and the
pure torsional mode (T) - have been evaluated and listed
in Table II. For the diagonal rib configuration, the flex-
ibility at the ribbed corner rather than the unsupported
corner is tabulated. The following observations can be
made:
(1) The horizontal partitions reduce the flexibilities
 S. K. KARK, S. HINDUJA AND A. COWLEY 215

in the panel and torsional mode but they are not Ph. D. TheSis, UMIST
very effective in the bending mode.
(2) The column with diamond-shaped ribs has low 3. W.F. DREYER (1966) Uber die Steifigkeit von
flexibilities all round. Werkzeugmaschinenstaendern und vergleichende
(3) The diagonal and the cross-rib configurations Untersuchungen an Modellen, Dissertation, T. H.Aachen
reduce the torsional and to a lesser extent, the
bending flexibility, but as expected they are not 4. S. HINDUJA and A. COWLEY (1972) The Finite
very effective against panel flexibility. Element Method applied to the Deformation Analysis of
thin-walled Columns, Proc. 12th M. T.D.R. Conf.
EXPERIMENTAL RESULTS
5. M. J. TURNER, R. W. CLOUGH, H. C. MARTIN and
Most of the modes found by computation were L.J. TOPP (1958) Stiffness and deflection analysis of
determined by exciting the column in two positions - complex structures, J. Aero Space Sci, 23
first by exciting at the mid-panel position to reveal all
the panel and bending modes, and then at the top corner 6. O. C. ZIENKIEWICZ and Y. K. CHEUNG (1964) The
to reveal the torsional modes. Only the open column finite element method for analysis of elastic isotropic
and the column with the cross-ribs have been experi- and orthotropic slabs, Proc. Inst. Ci V. Engrs., 28
mentally tested. The acceleration plots for these two
columns are shown in Figure 12. The resonance peaks
in the plots are marked with their frequency values and
their types of modal shapes. Low frequency modes are
very clear in the plot especially the distortion mode (D)
which occurs prominently at 414 Hz. The high frequen-
cy panel and pseudo-bending modes were, in general,
more difficult to locate; they could only be detected at
a very slow hand-driven speed with a small accelero-
meter.
The actual resonance frequencies are, as ex-
pected, generally lower than the computed frequencies
for the simple reason that the actual structure is more
flexible than the idealized model. The measured nat-
ural frequencies and the percentage error in the com-
puted values are also shown in Table 1. The error in
all the computed natural frequencies except two - the
distortion (D) and the first bending mode (B) - is less
than 10%. The relatively large error in the bending
and torsional natural frequencies is probably due to the
absence of the bolted flange joint in the finite element
model. The absence of the bolted joint has little effect
on the higher panel and pseudo -bending modes. This is
to be expected since in the pseudo-bending modes the
joint contributes a much smaller proportion to the total
strain energy and in the case of the panel modes, there
is hardly any joint rotation.

CONCLUSIONS

The results of this investigation has shown that

the open column has, besides the bending and torsional'
modes, a number of panel and pseudo-bending modes.
All the four types of ribbing investigated eliminate the
cross-sectional distortion mode. The diamond-shaped
ribs are by far the best type of ribbing configuration in-
vestigated. The diagonal and cross ribs are not very
effective in suppressing the panel and pseudo-bending
modes.

REFERENCES

1. S. HINDUJA (1971) Analysis of Machine Tool

Structures by the Finite Element Method, Ph. D. Thesis
UMIST

2. S.K. KARK (1974) Dynamic Analysis of Machine

Tool Structures by the Finite Element Method,
216 MODAL SHAPES OF MACHINE TOOL COLUMN STRUCTljRES

Mode

Comptd
0
Expt. Error
[Z]
Comptd Comptd
[gJ
Expt. Error
D---
Comptd
~
Comptd

Distortion
471.14 414 13.80% Absent Absent Absent Absent
Mode
Bending 488.00 382 27.75% 510.91 49l. 64 363 35.43% 494.80 546. 92
Modes 488.00 382 27.75% 599.45 49l. 64 363 35.43% 494.80 546.92
Panel 414.92 410 l. 2% 466.54 555.69 596 6.76% 843.98 800.50
Modes 488.86 466 4.9% 535.36 613.30 671 8.60% 908.98
PI 633.30 600 5.55% 672.46 734.43 766 4.12% 979.60
847.25 839 0.98% 879.24
1133.28 - -
Panel 925.69 894 3.54% 925 926.77 971 4.56% 966.13 -
Modes 955 952 .32% 955 956.94 1015 5.72% 1028.89 -
P2 1028.92 - - 1116.99 -
1165.23 - -

Pseudo 681.46 643 5.98% 323.19 747.20 713 4.8% 954.21

Bending 681.46 643 5.98% 409.00 747.20 713 4.8% 954.21
Modes 799.83 753 6.22% 532.25 857.66 865 0.84% 1046.20
81 799.83 753 6.22% 685.10 857.66 865 0.84%
983.62 968 1.61% 729.29 926.32
983.62 968 l.61% 793.06 1028.56
801.18 1028.56
892.97
90l.10
982.06
997.42

Pseudo
Bending 973 882 928.55 829 12.0% 1184.83 -
Modes 973 882 928.55 829 12.0% 1184.83 -
82

Torsional
1249 1002.42 918.05 941 2.43% 1240.11 1329.27
Mode T

Table I Computed and Experimental Natural Frequencies (Hz)

Position Direction
D [Z] ~
~
--- ~

Natural Frequency (Hz) 414.92 466.92 555.69 843.98 800.50

Node 14 u 4.94 3.46 3.53 l. 10 0.70

Natural Frequency (Hz) 488.0 510.91 491.64 494.80 546.92

Node 1 v l. 38 0.47 l.18 2.14 l. 65

Node 2 v 7.28 2.54 4.35 2.32 l. 65

Natural Frequency (Hz) 1249 1002.42 918.05 1240.11 1329.27

Node 1 u 0.29 0.073 0.08 0.19 0.13

Node 1 v 0.29 0.073 0.08 0.19 0.13

Table II Direct Modal Flexibility (x 10- 11 cms/dyne)

 S. K. KARK, S. HINDUJA AND A. COWLEY 217

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Figure 2 Classification of Modal Shapes of the Open Figure 4 Cross-Sectional Modal Shapes of Column with
Column Mesh 5-5-15
2 18 MODAL SHA PES OF MACHIN E TOOL COLUMN STRUCT U RES

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Figure 5 Natural Frequency Convergence Cur ves Figure 7 Box Column with diffe rent Ribbing Configura tion

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Figure 6 Cross-Sectional Modal Shapes of Unribbed Box Column

 S. K. KARK, S. HINDUJA AND A. COWLEY

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Figure 9 Cross-sectional Modal Shapes of the Column with Cross Ribs

220 MODAL SHAPES OF MACHINE TOOL COLUMN STRUCTURES

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Figure 10 Cross-sectional Modal Shapes of the Column with a Horizontal Partition

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No.6 (132927 Hz) No.8 (1440'85 Hz) No.9 (144085H z ) No.lO (1522,31 Hz)
No.7 (1373-58 Hz)

No.11 (1530 '61 Hz) No.12 (1530 ' 61 Hz)

Figure 11 Cross -sectional Modal Shapes of the Column with a Diamond -shaped Ribs
 S. K. KARK, S. HINDUJA AND A. COWLEY 221

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Figure 12 Acceleration VB Frequency Plot