Design of a Three-Axis Machine Tool Module

摘要

This report documents the design improvement process of the components in a tool module for a three-axis machine tool, which occurred during the period of March-April 2002 in support of a critical U.S. Army Materiel Command manufacturing technology (ManTech) program. Given a preliminary physical design, the objective was to apply finite element analysis (FEA) to predict stresses in the module and apply necessary design changes to increase the survivability and expected life of the device. The module is a component in a complex three-axis machine tool system. With a rigid structure assumption, an FEA model was developed, based on a preliminary design, and was used to predict stresses in the device when it is exposed to an expected loading condition. The effect of using contact elements in the FEA to calculate stresses of specific components was evaluated. Large calculated stresses that were concentrated in the angle brackets prompted model improvements and structural design changes, including grid refinement of the FEA mesh and increased angle bracket thickness, Based on the results of the analyses, recommendations were made for changes from the original design of the angle brackets.