臺灣博碩士論文加值系統

工具機的加工效率和表面精度都直接受到工具機的動態、靜態和剛性特性的影響。靜態和動態分析對於工具機的設計和改進至關重要，以確保在困難和苛刻的加工條件下具有良好的工作性能。在這項研究中，使用 SOLIDWORKS 建置虛擬的龍門型工具機模型，並簡化模型以利於後續的分析流程，後續使用 ANSYS Workbench 軟體對簡化模型進行模擬分析，以確定工具機的靜動態特性。透過有限元素建模方法研究模型的靜態和動態特性以研究機台的性能，特別是對工具機的結構、靜態、模態、頻譜和拓撲優化進行了初步分析，使用模態分析，我們發現前四個不同的頻率（22.5、28.9、40.6 和 47.4 Hz）和振動振型，這顯示出工具機結構薄弱的部分。進一步的靜態結構分析發現，主軸的變形量為 67.26μm。透過實際進行靜態剛性實驗，獲得了刀具和主軸的真實變形值，隨後將實際數據與有限元分析的結果進行比較，驗證了有限元分析的靜態和動態特性與實際結果趨勢雷同。接著修改分析的邊界條件和工具機模型，以確保分析結果與實驗結果近乎一致。 最終，實驗與分析的誤差僅在 1.56% 以內。確認實驗參數可用後，在主軸鼻端施加 5000 N 的載荷，根據暫態分析，刀尖暫態響應穩定時間約為 0.5 秒。最後在結構變形不變的情況下，結構最佳化的目的是減少機台重量並提高自然頻率以確保機台剛性提升。因此，為了獲得結構的最佳化，本研究進行拓撲優化分析，拓撲優化的最佳條件包括減輕機台重量、減少機台變形和提高工具機的自然頻率，這種分析方式加速了工具機結構優化的工作效率，也提高了工具機的開發能力，並為設計人員提供了多種具有成本效益的改善設計。

The machining efficiency and surface quality are both directly affected by the dynamic, static, and rigid nature of the high-precision machine tool. Static and dynamic analyses are essential for the design and improvement of precision machine tools to ensure good tool performance under difficult and demanding machining conditions. In this study, the performance of a high-precision machine tool was analyzed using its virtual model created using SOLIDWORKS. Reduced static analysis model using ANSYS Workbench software was conducted to establish the static deformation and static stiffness of the tool. Furthermore, the static and dynamic characteristics of the tool were explored using a finite element modeling approach to study their performance. In particular, the structure, static force, modal, frequency spectrum, and topology optimization of machine tools were primarily analyzed. Using model analysis, we find the first four different frequencies (22.5, 28.9, 40.6, and 47.4 Hz) and vibration type, which or showing a weak link. Further static structural analysis revealed that the deformation of the spindle was 67.26 μm. An experimental static rigidity analysis was performed, and the experimental deformation values of the tool and spindle were obtained. The static and dynamic characteristics, as well as the accuracy and efficiency of the finite element model, were verified by comparing the data with the FEA results. Subsequently, we modified the settings and analysis model to ensure that the analysis results were consistent with the experimental findings.
The error between the two results was within 1.56 %. For an applied load of 5000 N on the spindle nose, the tool nose transient response was 0.5 s based on transient
analysis. Under the condition that the structural deformation is as constant as possible, the lightweight structure may achieve the minimum weight and enhance the natural frequency; thus, the ideal structure will be obtained, and finite element analysis will then be performed. The optimal conditions for topology optimization include a lightweight structure, reduced structural deformation, and increased natural frequency of the structure. The developed method improves structural optimization, increases the ability of the product to be manufactured, and offers designers a variety of price-effective options.

Abstract......i
論文摘要.......iii
Acknowledgements......iv
Table of Contents......v
List of Tables......ix
List of Figures......x
Symbol Description......xiv
Chapter 1 Introduction......1
1.1 Aim and Scope......1
1.2 Introduction of Machine Tools......2
1.2.1 Machine Tool Accuracy......4
1.2.2 On-Machine Measuring......4
1.2.3 Machine Tools Market Challenges......5
1.2.4 Manufacturing Industry and Of MachineTools......6
1.2.5 Future Plan of Taiwan’s Smart Manufacturing Industry......7
1.3 Literature Review......7
1.4 Explanation of Research Activity......14
Chapter 2 The Proposed Gantry's Conceptual Design......17
2.1 Machine Tool and Gantry Type Large Machine......17
2.2 Gantry Mechanism......17
2.3 Types of Gantry Type MachineTool......18
2.3.1 The concept of double opposite motion......19
2.3.2 The Rack and Pinion-Based Double Motion Mechanism's......19
2.3.3 Backlash Problem......20
2.3.4 The Gear Backlash Compensation Mechanism (GBCM)......20
2.3.5 Gantry (Moving Bridge)......23
2.3.6 Fixed Bridge Design......24
2.3.7 3d Hybrid Design......24
2.4 Design of the Gantry Machine's Structure......25
2.4.1 Solution......26
2.5 Specifications Gantry Machine Tool......29
2.6 Structural Design and Machine layout......31
Chapter 3 Basic Theory and Experimental Equipment......33
3.1 The principle of finite element method......33
3.2 Fundamental Concepts in Vibration and Mode......35
3.2.1 Single-Degree-Of-Freedom Systems......36
3.3 Important Terms of Modal Analysis......36
3.3.1 Free Vibration......36
3.3.2 Natural Frequency......38
3.3.3 Damping......38
3.3.4 Damping ratio (ξ)......38
3.3.5 Over damping......39
3.3.6 Critical damping......39
3.3.7 Relevance, γ......40
3.4 Equilibrium Equation for Finite Element Analysis......40
3.5 Finite Element Calculation......42
3.6 Dimensional Analysis for Finite Element Computations......42
3.7 Experiment Apparatus......43
3.7.1 Leverage Scale......43
3.7.2 Millimar C 1200......44
3.7.3 Display and Operating Keys......44
3.7.4 Load Source......44
3.8 ANSYS Workbench......47
Chapter 4 Finite Element and Gantry Type MachineTool......48
4.1 Finite Element Model......48
4.2 Model Simplification......48
4.3 Create A Finite Element Model......50
4.3.1 Material properties......50
4.3.2 Mesh Configuration Setting......51
4.3.3 Mesh specifications/generation mesh independence study......52
4.4. Model Analysis......53
4.4.1 Boundary Condition Setting......54
4.4.2 1st Mode Shape......54
4.4.2 2nd Mode Shape......55
4.4.3 3rd Mode Shape......55
4.4.4 4th Mode Shape......55
4.4.5 5th Mode Shape......56
4.4.6 6th Mode Shape......56
4.5. Static Analysis......57
4.5.1 Boundary condition setting......57
4.5.2 Static Analysis - Self-Weight Deformation......59
4.5.3 Static Analysis, X axial Cutting force 5000N......60
4.5.4 Static Analysis, Y axial Cutting force 5000N......61
4.5.5 Static Analysis, Z axial Cutting force 5000N......62
4.5. Spectrum Analysis......62
Chapter 5 Experimental Testing and Verification......65
5.1 Experiment On the Static Rigidity......65
5.2 X-Axis Rigidity Test of the Whole Machine......66
5.3 Rigidity test of the Y-axis of the whole machine......67
Chapter 6 Structural Optimization......69
6.1 Optimization Objective......69
6.2 Optimization Process......71
6.2.1 Optimally Criteria method......72
6.3 Analysis condition setting......72
6.4 Analysis results......74
6.5 Workbench optimization results......75
6.4.1 Before Optimization and After Optimization......75
6.6 Cross Rail optimization results......77
6.6.1 Before Optimization and After Optimization......77
Chapter 7 Conclusion and Future Prospects......79
7.1 Research Directions for the Future......80
7.2 Future Works......81
References......82
Extended Abstract......84

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