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Design, Static and Dynamic Analysis of Crossbeam of a Gantry Milling Machine

Zamani, Hamid | 2014

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  1. Type of Document: M.Sc. Thesis
  2. Language: Farsi
  3. Document No: 45276 (08)
  4. University: Sharif University of Technology
  5. Department: Mechanical Engineering
  6. Advisor(s): Movahhedy, Mohammad Reza; Akbari, Javad
  7. Abstract:
  8. Gantry milling machines are one of the types of machine tools that have vast application in various industries. Considering requirements such as quality and roughness of work pieces which are becoming restricted day after day, it is necessary that various parts of this machine have sufficient functionality and precision so that it can fulfill the quality requirements; and production of these expensive machines be cost-effective. One of the most important parts of a gantry milling machines is its crossbeam that undergoes deflections when exposed to applied forces during work conditions and can have undesirable effect on work piece precision. Therefore, the goal of this research is to design and analyze the crossbeam of this machine in order to achieve desirable static and dynamic characteristics the most important of which are deflection and natural frequency of the structure.
    The adopted approach of this project is based on the design optimization. In this approach, the structure is first analyzed from the standpoint of topology and general scheme. Design requirements in this context is that the structure should have sufficient rigidity while the weight of the structure is the minimum possible so that it is optimized regarding issues of cost, manufacturing and energy consumption in transportation or under work conditions. For this purpose, FEM softwares with topology optimization capabilities are used. After topology optimization, a design is used that has the most similarity to the optimized structure; and manufacturing requirements is considered in it or in a general word doesn't have complicated manufacturing process. At the next step, the model's dimensions are optimized to achieve desirable characteristics. After this step, topology optimization can be used again and the mass can be reduced until the structure rigidity doesn't exceed desirable extent. Stiffeners can also be used for design improvement.
    At the end of this research, dynamic stability of machining process is analyzed which results in proper selection of cutting parameters to avoid chatter while increasing material removal rate
  9. Keywords:
  10. Natural Frequency ; Static Analysis ; Dynamic Analysis ; Topology Optimization ; Gantry Milling Machine ; Transverse Beam ; Size Optimization

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