Structural investigation of steel-reinforced epoxy granite machine tool column by finite element analysis

• Published in: Proceedings of the Institution of Mechanical Engineers. Part L, Journal of materials, design and applications Journal of materials, design and applications, 2019-11, Vol.233 (11), p.2267-2279
• Main Authors: Venugopal, Prabhu Raja, Kalayarasan, M, Thyla, PR, Mohanram, PV, Nataraj, Mahendrakumar, Mohanraj, S, Sonawane, Harshad
• Format: Article
• Language: English
• Subjects: Cast iron; Columns (structural); Configuration management; Configurations; Damping capacity; Design optimization; Dynamic characteristics; Equivalence; Finite element analysis; Finite element method; Granite; Machine shops; Machine tools; Machining; Machining centres; Mathematical models; Modal analysis; Modulus of elasticity; Resonant frequencies; Stiffness; Structural design; Structural vibration; Surface finish
• ISSN: 1464-4207; 2041-3076
• DOI: 10.1177/1464420719840592

Higher damping with higher static stiffness is essential for improving the static and dynamic characteristics of machine tool structures. The structural vibration in conventional machine tools, which are generally made up of cast iron and cast steel, may lead to poor surface finish and the dimensional inaccuracy in the machined products. It leads to the investigation of alternative machine tool structural materials such as concrete, polymer concrete, and epoxy granite. Although epoxy granite has a better damping capacity, its structural stiffness (Young's modulus) is one-third as compared to cast iron. Therefore, the present work represents optimization of the structural design of the vertical machining center column by introducing various designs of steel reinforcement in the epoxy granite structure to improve its static and dynamic characteristics using experimental and numerical approaches. A finite element model of the existing cast iron vertical machining center column has been developed and validated against the experimental data obtained using modal analysis. Furthermore, finite element models for various epoxy granite column designs have been developed and compared with the static and dynamic characteristics of cast iron column. A total of nine design configurations for epoxy granite column with steel reinforcement are evolved and numerical investigations are carried out by finite element analysis. The proposed final configuration with standard steel sections has been modeled using finite element analysis for an equivalent static stiffness and natural frequencies of about 12–20% higher than cast iron structure. Therefore, the proposed finite element model of epoxy-granite-made vertical machining center column can be used as a viable alternative for the existing column in order to achieve higher structural damping, equivalent or higher static stiffness and, easy and environmental-friendly manufacturing process.