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Efficient quantification of free and forced convection via the decoupling of thermo-mechanical and thermo-fluidic simulations of machine tools

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Glaenzel J. , Ihlenfeldt S. , Naumann C. , Putz M.

Journal of Machine Engineering

2018

tom Vol. 18, No. 2

41--53

Thermo-elastic deformations represent one of the main reasons for positioning errors in machine tools. Investigations of the thermo-mechanical behaviour of machine tools, especially during the design phase, rely mainly on thermo-elastic simulations. These require the knowledge of heat sources and sinks and assumptions on the heat dissipation via convection, conduction and radiation. Forced convection such as that caused by moving assemblies has both a large influence on the heat dissipation to the surrounding air. The most accurate way of taking convection into account is via computational fluid dynamics (CFD) simulations. These simulations compute heat transfer coefficients for every finite element on the machine tool surface, which can then be used as boundary conditions for accurate thermo-mechanical simulations. Transient thermo-mechanical simulations with moving assemblies thus require a CFD simulation during each time step, which is very time-consuming. This paper presents an alternative by using characteristic diagrams to interpolate the CFD simulations. The new method uses precomputed thermal coefficients of a small number of load cases as support points to estimate the convection of all relevant load cases (i.e. ambient conditions). It will be explained and demonstrated on a machine tool column.

Flexible coupling of drive and guide elements for parallel-driven feed axes to increase dynamics and accuracy of motion

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Peukert C. , Merx M. , Müller J. , Ihlenfeldt S.

Journal of Machine Engineering

2017

tom Vol. 17, No. 2

77--89

Productivity enhancement is achievable by increasing the dynamics of machines. This can be accomplished by decreasing the moving mass or by increasing the driving forces. One possibility for increasing the drive forces lies in the use of multiple parallel-acting actuators. Because of the mechanical coupling between the drives, undesirable interference of the actuators occurs. This limits the control bandwidth of the feed axis. Feed axes of machine tools are mostly equipped with linear guides fitted with rolling elements. Since they dispose of just one degree of freedom, small errors in their alignment or thermally induced errors cause constraining loads. In this paper compliant mechanisms are used to mechanically decouple the slide from the guide and drive elements. The application of flexible joints in gantry axes with linear motors and ball screws is investigated. The dynamic behaviour of the feed axis components are modelled using the Finite Element Method. By applying the modal reduction technique, the dynamic behaviour is included in an elastic multibody simulation. With the mechanical decoupling of the drive and guide elements it is possible to increase the control bandwidth of the system. Deviations in motion may also be corrected with parallel-driven feed axis by applying compliant mechanisms.