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Finding the Natural Frequencies and Mode Shapes for Vibration

Analysis of Upright Drilling Machine

J S Saini, Non-member
M P Garg, Non-member
T Nanda, Non-member

Increasing demand for greater accuracy and output from machine tools has caused vibration problems to gain
importance. Both forced and sustained vibrations are known to be prejudicial to accuracy and output. The present work
includes finding the natural frequencies and mode shapes of F-shaped structures using finite element method. A framed
structure is proposed, which approximates the properties and the shape of the F-structure. Natural frequencies and mode
shapes are obtained by making a computer program in C++. Work is then extended to vibration analysis of upright
drilling machine structure. Finite element modelling of the drilling machine structure is done. Thereafter, the natural
frequencies and mode shapes are obtained taking into consideration the mass of work pieces placed over the machine table.

Keywords: Vibration analysis; Drilling machine; F-shaped structure; Two-noded frame element; Finite element method

NOTATION vibration analysis of machine tool structure is to sustain the


A : area of element useful oscillations and eliminate the unwanted ones.

E : Young’s modulus of elasticity Bellmon and Casti 1 proposed differential quadrature (DQ)
method for vibration analysis of plates. DQ method
I : mass moment of inertia approximates the partial derivative of a function with respect to
[K] : system stiffness matrix spatial discrete points using weighted linear sum of the function
e values at all discrete points in the overall domain of spatial
[k] : elemental stiffness matrix variable. The method is able to rapidly compute accurate
[M] : system mass matrix solutions of partial differential equations using only a few grid
e points in the respective solution domain. The limitations of the
[m] : elemental mass matrix
method is that the system of equations to be solved become ill
[N] : matrix of shape functions conditioned, if the number of grid points chosen becomes large.
{x} : displacement vector The same method was later used by Liew and Teo2 for vibration
analysis of rectangular plates.
x}
{ && : acceleration vector
Wei3 used discrete singular convolution (DSC) method for
r : density of material of structure analysis of mechanical behaviour of plates. It was shown that
w : natural frequency DSC approach provided more than 10 significant figures
accuracy for the first hundred eigen mode of regular plate with
INTRODUCTION simply supported boundary conditions. Wei, et al 4 later
Today, the increasing demand for accuracy and output has extended the previous implementation of DSC algorithm for
caused vibration problems to gain importance. Both forced and plate analysis with mixed boundary condition.
sustained vibrations are known to be prejudicial to accuracy Ewins5 applied modal analysis for vibrational analysis of
and output. All machine tools give rise to vibrations. sandwiched beams for finding natural frequency and
Deterioration in machine condition always produces a corresponding mode shapes. Srivastwa6 extended the Ewins’s5
corresponding increase in vibration levels. Vibration signals are work. The main contribution of his work is the development of
one of the most reliable parameter used in machine health dynamic stiffness matrix (DSM) based structural dynamic
monitoring to check machine condition. The purpose of the modifications in physical spaces for which automatically
J S Saini and T Nanda are with the Department of Mechanical generated data from the spatial parameters of an updated model
Engineering, Thapar Institute of Engineering and Technology, Patiala of a structure can be employed. It also includes the development
147 004; while M P Garg is with the Department of Mechanical of sensitivity derivates based optimal modification techniques.
Engineering, M M Engineering College, Mullana, District Ambala,
Haryana. A more promising approach for developing a solution for
This paper was received on July 21, 2004. Written discussion on the paper structural vibration problems is provided by an advanced
will be entertained till December 31, 2005. numerical discretisation scheme, such as, finite element

164 IE (I) Journal—MC


method (FEM). The problem of free vibration of beams is of Width = 400 mm
considerable practical interest because of wide application in
civil, mechanical and aircraft industry. Vibration of cantilever
beam filled with a liquid was investigated by Chan and Leung7.
Chan and Zhang8 extended the Chan and Leung7 work by
concluding that, the beam can be modelled as a cantilever beam

Length = 550 mm
loaded with uniformly distributed load. Wang, et al 9 extended
Chan and Zhang’s8 method to a more general case, a beam
loaded with two sections of practically distributed mass.
Rangarajan10 used FEM for modelling the joints in the structure.
Firstly by using IDEAS software, the natural frequencies of the
F-shaped structure was found without considering the joints.
Then the effect of joints on the dynamic behaviour of the
structure was found out using FEMs.
Thick cylindrical sections are often encountered in most of the
machine tool structures. Early investigations of hollow
cylinders, based on linear three-dimensional theory of
elasticity, was investigated by Shah and Sackman11. Guan and
Wei12 extended the work by proposing a different mode Figure 1 F-structure for FE analysis
classification method for finite length thick cylinders, based
upon cylinder’s three-dimensional mode shapes. All the analysis of actual structure is expensive and it requires more
vibration modes of finite length thick cylinders could be computational effort. However, most of the drilling machines
identified uniquely. The FEM was used to calculate the natural are supposed to be having a F-shaped structure.
frequencies and corresponding mode shapes. In order to verify The simplified structure of a drilling machine, which is
the mode classification, measurements on similar thick considered for finite element analysis, is shown in Figure 1
cylinders were performed. with dimensions. The cross-section of the structure is taken as
For vibration analysis of plates, excellent work has been done 36 mm × 36 mm.
by Gorman13, who constructed the annular finite elements with
linear variable thickness to study lateral vibrations of plates The assumptions made while finite element are modelling of
having variable thickness, mainly plates of linearly variable the structure are:
thickness, and obtained very good results. But when the plate ● In practical case, the machine structure is a three-
thickness varies with the radius in parabolic or other dimensional model but for simplification, it is
complicated forms, the convergence and the accuracy is poor. considered two-dimensional.
Ren and Chen14 employed annular plate elements with variable
thickness for analysing the free, lateral vibrations of thin ● Bolted joints in the practical structure are not
annular and circular plates, whose thickness was permitted to considered in FE modelling and hence the joints and
vary with radius. It was found that the convergence and boundary conditions are considered to be rigid and
accuracy of the method was better than similar studies in which fixed. The displacements at the grounded node are
annular elements with uniform thickness or linearly variable considered to be zero.
thickness were used. Plates in buckled state may be expected to ● Damping is neglected.
survive under dynamic disturbances. Chan and Chen15 used a
nine-noded element to study the free vibration of a buckled ● Mass overlapping effects at the cross-joints are not
composite plate after impact. It was pointed out that considered.
fundamental frequency of buckled plate increases with
increasing pre-stress, reaches a maximum, and then decrease as ANALYSIS PROCEDURE
load is increased further. Finally, the frequency drops to zero The various steps in the finite element vibration analysis of a
and another unstable state prevails. structure are:
Shiau and Teng16 studied free vibration behaviour of buckled 1. The structure is divided into 12 two-noded frame
composite plates by using a high precision triangular element. element and 13 nodes. Each node has two
Results showed that the fundamental mode shifted from the displacements and a rotational degree of freedom.
first mode to second due to squeezing effect of the in plane force Therefore, each element has six degrees of freedom and
on the plate. total structure is having 39 degrees of freedom. The
PROBLEM FORMULATION OF F-SHAPED discretised structure is shown in Figure 2.
STRUCTURE 2. Elemental connectivity table is prepared for the
In general, machine structures are very complex due to various structure, which shows the connectivity of each pair of
functional elements or component. Therefore, modelling and nodes.

Vol 86, October 2005 165


4 3 2 1 0 Table 2 Comparison of results

Natural From C++ Results from Error, %


frequency, Hz program Rangarajan10
5 (present
investigation)

6 7 8 9 1 Mode 1 35.73 38.84 – 8.70

Mode 2 128.40 114.90 + 10.50

Mode 3 182.60 178.30 + 2.35


11
Mode 4 358.20 366.50 – 2.30

Mode 5 888.50 907.00 – 2.08


12
Mode 6 1024.00 988.70 + 3.40

Figure 2 F-structure with node numbers


Table 2 shows that the results of present investigation
(developed C++ program) and those Rangarajan10 are
3. Elemental mass matrices and stiffness matrices are
comparable.
computed using equations (7) and (8) in Appendix.
4. Using the conventional rules of assembly in FEM, The first two mode shapes obtained from C++ program are
system mass and system stiffness matrices are compared with the first two mode shapes obtained from IDEAS
obtained. software and shown in Figure 3.

5. System mass and stiffness matrices are modified From Figure 3(a), it is seen that the fundamental mode shapes
according to boundary condition, ie, the displacements obtained from C++ program and IDEAS software10 show
at the fixed node are zero. close agreement. From Figure 3(b), it is observed that at node
numbers 8, 10, 11 (Figure 2), there is some deviation in the
6. The eigen value thus obtained can be solved using
displacement given by C++ program and IDEAS software. But
inverse iteration technique. Inverse iteration is a
this is acceptable up to a reasonable limit. Hence, the C++
procedure, which converges to eigen vectors
program for vibrational analysis of F-shaped structure is
corresponding to the eigen value having smallest
validated.
modulus.

PROGRAM VALIDATION
For validation of the program, results published by 800
Rangarajan10 are taken as reference. Rangarajan used the
structure whose details are shown in Table 1 and used IDEAS
software for analysis. The present work uses the same structure 500
(as used by Rangarajan) to facilitate validation. The results have
been compared in Table 2 and Figure 3. Displacements in
Figure 3 are shown after multiplying the actual displacements
400
by a factor of 1000 (for clarity).
For vibration analysis F-shaped structure is discretised into
12 elements and 13 nodes as shown in Figure 2. 300

Table 1 Details of the structure (used by Rangarajan)


200
From C++ program
Mass density, r, kg/m3 7800
From IDEAS
Young’s modulus of elasticity, E, GPa 200 100
Length

Mass moment of inertia, I 13.9968e-8m3

Area of the element, A 12.96e-4m2


0
Number of elements 12 –100 0 100 200 300 400 500
Width
Number of nodes per element 2

Total number of nodes 13


Figure 3(a) First three mode shapes from C++ program

166 IE (I) Journal—MC


700

600

500

400

300

200
From C++ program

From IDEAS
Length

100

0
0 100 200 300 400 500
Width
Figure 4(a) Drilling machine
Figure 3(b) Mode Shapes aroung second natural frequency

VIBRATION ANALYSIS OF UPRIGHT DRILLING 3 2 1 0


MACHINE STRUCTURE
(2) (1) (0)
(3)
The assumptions made in the vibration analysis of drilling
machine structure are: 4
● In practical case, the drill machine structure is three- (4)
dimensional, but for the sake of simplicity it is
considered two-dimensional. 5

● The joints are assumed to be rigid and the structure is (5)


considered to be one piece. 7 8 9
6
● Damping is neglected.
(9) (6) (7) (8)
● Switches, levers, broader base of the machine, motor
10
driving the drill, power transmission devices are not
considered. These in no way contribute towards the (10)
rigidity of the drill machine structure.
11
● Displacements at the grounded node are assumed to be
zero. (11)

FE Modelling of the Drilling Machine Structure 12


Figure 4(a) shows an upright drilling machine. It is modelled as
Figure 4(b) FEA model of the drilling machine
a F-structure as shown in Figure 4(b).
The FE model of the drilling machine structure is obtained as: ● Since, drill chuck of the drilling machine is not
contributing towards the rigidity of the machine
● Framed structure (Figure 4(b)) is discretised into 12
structure, it is considered as a point mass at the node
elements and 13 nodes.
number 0 of the framed structure.
● Element numbers 0, 1, 2 of the framed structure
● Element numbers 3, 4, 5, 9 of the framed structure
(Figure 4(b)) represents the column of the drilling
represent pillar of the drilling machine structure. Pillar
machine structure. Frame type elements having
of the drilling machine is having circular cross-section.
rectangular cross-section are taken which approximate
the column of drilling machine structure. In drilling ● Arm supporting the machine table is represented by
machine structure there is variation in thickness along element numbers 6, 7 and 8 of the framed structure. The
the length of the column, but for the analysis, the cross- arm of the drilling machine is tapered, more width near
section of each of these elements is taken constant. the pillar and less width at the machine table end. Total

Vol 86, October 2005 167


Table 4 Values of properties used

13 Mass density, r, kg/m3 7800


7
Young’s modulus of elasticity, E, GPa 200

Number of elements 12

Number of nodes per element 2


36 Total number of nodes 13
Figure 4(c) Arm of drilling machine structure

RESULTS AND DISCUSSION


Using the program, already validated for vibration analysis of
10 F-shaped structure, vibration analysis of upright drilling
13 7
machine is done. Table 5 shows the first five natural frequencies
of drill machine structure.
The first four mode shapes obtained from the C++ program
12 12 12 are shown in Figure 5.
Figure 4(d) Frame elements representing the arm of drilling machine From Figure 5, it is seen that in the fundamental mode shape
(all dimensions in cm) (corresponding to fundamental natural frequency 75.72 Hz),
node numbers 3 and 4 (Figure 4(b)) show displacements along
length of arm is divided into three frame elements positive x-axis, whereas node numbers 6 and 10 (all
having same length and different widths as shown in corresponding to pillar of drilling machine structure) show
Figure 4(c) and Figure 4(d). displacements along negative x-axis, from the corresponding
These three elements will approximate the shape of arm of positions on the undeformed structure. Node numbers 0, 1, 2
drilling machine structure. (which corresponds to column of drill machine) show
displacements above the undeformed structure and node
● Base of the drilling machine is represented by element numbers 7, 8, 9 (which correspond to arm of drilling machine)
numbers 10, 11 of the framed structure. The elements vibrate below the undeformed structure.
are having rectangular cross- section.
In the second mode shape (around second natural frequency),
● Machine table of the drilling machine does not column of the drilling machine (ie, node numbers 0, 1, 2) show
contribute towards the rigidity of the structure. So, in displacements above the undeformed drilling machine
FE modelling, it is taken as a dead mass (54.5 kg) at structure. Nodes corresponding to pillar of drilling machine (ie,
node number 9 of the framed structure. node numbers 3, 4, 5, 6, 10) shows displacement along negative
Dimensions of the Elements x-axis from the undeformed structure. Arm supporting the
The dimensions of the various elements and other properties in machine table (ie, element numbers 6, 7, 8 from Figure 4(b),
the framed structure are given in Tables 3 and 4. vibrates above the undeformed structure.
In the third mode shape (corresponding to third natural
Table 3 Dimensions of various elements frequency), node number 0, which carries the weight of drill
chuck shows displacement below and node number 1 shows
Element Length, Width, Thickness, Diameter,
displacements above the undeformed drilling machine
number cm cm cm cm
structure. Also, nodes representing the pillar (node numbers 3,
0 15.00 20 10.00 — 4, 5, 10) and base (node number 11) show large displacements
1 15.00 20 10.00 — from the undeformed structure.
2 10.00 20 10.00 — So, from Figure 5, by studying the first four mode shapes, the
3 18.67 — — 10 vibration pattern of drilling machine structure can be
4 18.67 — — 10 visualised.
5 18.67 — — 10 In the present analysis work, natural frequencies are obtained
6 12.00 13 13.00 — for different loads placed on the machine table.
7 12.00 10 7.00 —
A Mass of 20 kg is Placed on the Machine Table
8 12.00 7 7.96 —
First five natural frequencies obtained from the C++ program
9 26.00 — — 10 are given in Table 6.
10 7.00 14 14.00 —
Now the fundamental mode shape obtained under a load of
11 42.00 18 11.00 — 20 kg is superimposed over the fundamental mode of drill

168 IE (I) Journal—MC


1600 1600

1400 1400

1200 1200

1000
1000

800
800

600
Undeformed 600
machine structure Undeformed
400 Mode shape 1 machine structure
400
Mode shape 2 Mass zero
Length

200 Mode shape 3

Length
Mode shape 4 200 Mass 20 kg
0
–200 0 200 400 600 0
Width –100 0 100 200 300 400 500 600

Width
Figure 5 First four mode shapes of the structure
Figure 6(a) Fundamental mode shapes of the structure

structure without load (as shown in Figure 6(a)). However, displacements of column of the drilling machine (ie,
Comparing the values of fundamental frequencies in Tables 5 node numbers 0, 1, 2) and arm of the drilling machine (node
and 6, it is observed that the value of fundamental frequency, numbers 7, 8 and 9) are overlapping in the two cases.
when an additional mass of 20 kg is placed on the machine table Figure 6(b) shows the mode shapes around second natural
is lesser (57.84 Hz) as compared to the case when no additional frequency for the two cases, ie, when no additional load is
load is there on the machine table (ie, 75.72 Hz). So, placed over the machine table and when a load of 20 kg is placed
displacement of drill machine structure in the present case over the machine table.
should be more when compared to the previous case. This is
evident from Figure 6(a), where it is observed that nodes Comparing Tables 5 and 6 for the second natural frequencies, it
representing pillar of drilling machine structure (ie, node is observed that value of natural frequency, when a mass of 20 kg
numbers 3, 4, 5), in the present case, show larger displacements is placed over the machine table is comparatively less (ie,
along positive x-axis than the corresponding positions on the 88.90 Hz) than the corresponding value in Table 5, ie, 93.06 Hz.
fundamental mode shape of drill machine structure without
1600
exposure to additional mass on the machine table.

Table 5 First five natural frequencies as obtained from programs 1400

Mode number Frequency, Hz


1200
1 75.72

2 93.06
1000
3 260.90

4 528.50 800

5 671.50
600
Undeformed
Table 6 First five natural frequencies obtained from programs machine structure
400
Mode number Frequency, Hz Mass 20 kg
Length

1 57.84
200 Mass zero
2 88.90

3 287.60 0
–200 0 200 400 600
4 525.40 Width
5 644.40 Figure 6(b) Mode shapes around second natural frequencies

Vol 86, October 2005 169


From Figure 6(b), it is seen that when a mass of 20 kg is placed 1600
over the machine table, nodes representing column of drilling
machine structure (node numbers 0, 1, 2) of the framed structure
1400
vibrate above and nodes representing pillar of drilling machine
(node numbers 3, 4, 5, 6, 10) vibrate below the corresponding
positions of the case, when no additional mass is placed over the 1200
machine table.
A Mass of 40 kg is Placed over the Machine Table
1000
Natural frequencies are obtained, when a load of 40 kg is placed
over the machine table, as given in Table 7.
Figure 7(a) shows the fundamental mode shapes, when 800
additional masses of 20 kg and 40 kg are placed over the machine
table.
600
From Figure 7(a), it is seen that when an additional mass of
40 kg is placed over the machine table, nodes representing pillar
Undeformed
of drilling machine structure (ie, node numbers 4, 5, 6) of the 400 machine structure
framed structure, show slightly more displacements along Mass 20 kg
positive x-axis than the corresponding positions on the

Length
fundamental mode shape of the case, when a mass of 20 kg is 200 Mass 40 kg
placed over the machine table. This is evident from the value of
fundamental frequencies given in Tables 6 and 7. As the value is
less (ie, 9.25 Hz) when a mass of 40 kg is placed over the machine 0
–200 –100 0 100 200 300 400 500
table, then the corresponding value in table (5.4), ie, 57.84 Hz.
Width
However, displacements of nodes corresponding to column (ie,
Figure 7(b) Mode shapes around second natural frequencies
node numbers 0, 1, 2) and to pillar (ie, node numbers 7, 8, 9) of
the framed structure in the two cases (given in legend) are Figure 7(b) shows mode shapes around second natural
overlapping. frequencies for two cases, ie, when masses of 20 kg and 40 kg are
Table 7 First five natural frequency as obtained from program placed over the machine table.
From Figure 7(b), it is observed that when a mass of 40 kg is
Mode number Frequency, Hz placed over the machine table, arm of drilling machine (ie, node
1 9.25 numbers 7, 8, 9) shows displacements below the corresponding
positions on the second mode shape of drill machine structure,
2 120.90
of the case when a mass of 20 kg is placed over the machine
3 285.30 table.
4 525.30 Displacement of nodes corresponding to pillar (ie, node
numbers 3, 4, 5, 6 and 10) and base (node number 11) and column
5 626.60 (ie, node numbers 0, 1, 2) are overlapping in the two cases
discussed.
1600
CONCLUSIONS
1400 1. With increase in the mass of the work piece, which is
placed on the machine table, there is a fall in the
1200
fundamental frequencies of the machine structure.
1000 2. Higher natural frequencies (ie, from third natural
frequency and onwards) are not much affected with increase
800
in mass of work piece.
600 3. With increase in mass of the work piece, relative
Undeformed displacement of arm and column of drilling machine is not
400 machine structure
much affected, but displacement of pillar of drilling
Length

Mass 20 kg
200 machine structure increases from the corresponding
Mass 40 kg positions on the undeformed structure.
0
–100 0 100 200 300 400 500 600 ACKNOWLEDGEMENT
Width
The authors would like to thank Dr H N Chandrawat,
Figure 7(a) Fundamental mode shapes of structure Professor and Dean (Research and Sponsored Projects) (Retd),

170 IE (I) Journal—MC


Thapar Institute of Engineering and Technology, Patiala, and APPENDIX
presently Principal, Amritsar College of Engineering and Mathematical Formulation of the Problem
Technology, Amritsar, for his help, comments and suggestions, The prescription for deriving the characteristics of a finite element of a
which improved the work done in the paper. continuum will be discussed in detailed mathematical form.
The basic matrix equation for dynamics of a system is given by
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Vol 86, October 2005 171

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