Professional Documents
Culture Documents
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
E : Youngs 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 Ewinss5
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
Length = 550 mm
loaded with uniformly distributed load. Wang, et al 9 extended
Chan and Zhangs8 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 cylinders 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.
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
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
Number of elements 12
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
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.
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
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),