Topology Optimization of Machine Tools to improve the Stability in high performing Metal Cutting Processes

Stand: 28.10.05

EM5/ALH

Gebr. HELLER Maschinenfabrik GmbH Dr. Gerhard Kehl, Harald Altstdter 09.11.05 1
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Manufacturing Systems for Automotive Industry

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09.11.05

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Simulation Disciplines at Machine Tools

Thermal
MCH 250 G MCH 250 HSM

MCH 350 GE MCH 250 C

Static

Dynamic

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Mechanical Structures in complex Systems

17 Volumes 12 elastic Couplings

Designspace

Non-Desigarea 2 Volumes 3 Couplings

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Modeling of the mechanical Structure for Optimization

Non-Design Area

Designspace

Simulation Model

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Optimization Strategies
Static Topology Optimization
with weighted load cases (up to now max. 44) moving loads (weight) acceleration loads (quasi-static) process loads

Combined Topology Optimization

Amplit ude

Ausgangsmodell Opt imierungsergebnis

static loads + eigenfrequencies specific frequency constraints f1 = 60 Hz > f1* f2 = 90 Hz > f2* f3 = 120 Hz > f3*
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(Nachgiebigkeit sf requenzgang)

Frequenz
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Initial model for head (Realistic boundary conditions)

Flexible beam elements for boundary conditions

Beam elements attached to rigid mass

Loadcase 2
(y-direction)

Loadcase 1
(x-direction)

Beam elements attached to rigid mass

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Static optimization

Minimize: Maximize of { abs(ux), abs(uy)} Mass < Mass* = 35%

Number Eigenfrequency 1 ~0 The rigid mass is no 2 ~0 more 3 ~0 4 2.4 attached to structure 5 3.0 6 3.5

!!!!

Important: the static optimization showed that the frequency responses also have to be considered in the optimization.
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Frequency optimization

0.4

Maximize the eigenfrequencies from f1 to f6 Mass < Mass* = 35%

0.35

0.3

0.25

0.2

0.15

Mass constraint is not active

0.1

0.05

0 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41

Number 1 2 3
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Eigenfrequency 83 105 112

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Shaft hardly attached to structure. Important: Model the correct physical boundary conditions. The optimization should include static and frequency results.
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Combined static and frequency optimization

Purpose: To improve the static stiffness for both loadcases including constraints on the eigenfrequencies.

Objective:

Minimize: Maximize of { abs(ux), abs(uy)} f1 > f1* = 60 Hz f2 > f2* = 90 Hz f1 > f1* = 75 Hz f2 > f2* = 100 Hz f3 > f3* = 125 Hz f4 > f4* = 150 Hz f5 > f5* = 175 Hz f6 > f6* = 200 Hz

Constraints: Mass < Mass* = 35%

Example 1

f3 > f3* = 120 Hz f4 > f4* = 150 Hz f5 > f5* = 180 Hz f6 > f6* = 210 Hz

Example 2

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Combined static and frequency optimization: Topology

Example 1:
Number 1 2 3 4 5 6

Example 2:
Initial 48 60 94 137 260 265 example 2 75 101 145 191 268 377

Number 1 2 3 4 5 6

Initial 48 60 94 137 260 265

example 1 60 90 137 181 256 345

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Examples for Topology optimized Machine Components

Tool Changer Arm

Rod and Plain Eye

hydr. Rundtisch Brake

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Examples for Topology optimized Machine Components

Machine Stand
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Examples for Topology optimized Machine Components

Machine Stand

Milling and Boring Carriage

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09.11.05

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