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Development of a vibration free machine structure for high-speed micro-milling center

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Abstract

The demand of ultra-precision micro-machine tools is growing day by day due to exigent requirements of miniaturized components. High accuracy, good dimensional precision and smooth surface finish are the major characteristics of these ultra-precision machine tools. High-speed machining has been adopted to increase the productivity using high-speed spindles. However, machine tool vibration is a major issue in high-speed machining. Vibration significantly deteriorates the quality of micro-machining in terms of dimensional precision and surface finish. This article describes a design methodology of a closed type machine structure for vibration minimization of a high-speed micro-milling center. The rigid machine structure has provided high stiffness and the damping capability to the machine tool without utilizing vibration absorbers. The models of the machine structures have been generated and assembled in AutoCAD 3D. The performance of the integrated micro-milling machine tools was determined by finite element analysis. The best model has been selected and proposed for manufacturing. Additionally, simulation results were validated by comparing with experimental results. Eventually, after manufacturing and assembly, experiments have been performed and it was observed that the amplitude of vibration was approaching towards nanometer level throughout the working range of the high-speed spindle. The machine tool was capable to fabricate miniaturized components with smooth surface finish.

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Acknowledgements

The design of the vibration free machine structure has been applied for Indian Patent with application no. 201931049978, which has been published on 24th July 2020.

Funding

This research work has been financially supported by Department of Science and Technology (DST), India, under project number ECR/2016/001956.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology (ISM) Dhanbad, Jharkhand, 826004, India

    Arnab Das, Shashank Shukla, Mohan Kumar, Chitransh Singh, Madan Lal Chandravanshi & Vivek Bajpai

Authors
  1. Arnab Das
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  2. Shashank Shukla
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  3. Mohan Kumar
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  4. Chitransh Singh
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  5. Madan Lal Chandravanshi
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  6. Vivek Bajpai
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Contributions

Vivek Bajpai has planned and defined the methodology of the research work and arranged necessary funding. Arnab Das has performed the simulations. Shashank Shukla has participated in the purchasing work and performed the assembly of the machine tool. Arnab Das, Mohan Kumar and Chitransh Singh have performed the experiments and analysis. Madan Lal Chandravanshi have provided the necessary instruments for experiments and prepared experimental planning. Arnab Das and Vivek Bajpai have participated in paper writing and necessary revisions of it. All authors read and approved the final manuscript.

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Correspondence to Vivek Bajpai.

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Das, A., Shukla, S., Kumar, M. et al. Development of a vibration free machine structure for high-speed micro-milling center. Int J Adv Manuf Technol 116, 3489–3506 (2021). https://doi.org/10.1007/s00170-021-07533-1

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  • DOI: https://doi.org/10.1007/s00170-021-07533-1

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