[논문]CNC 공작기계 스프레쉬 가드의 안전성을 위한 충격 시험에 대한 유한요소법 적용에 관한 연구

김태원; 최진우

doi:10.7735/ksmte.2013.22.5.782

CNC 공작기계 스프레쉬 가드의 안전성을 위한 충격 시험에 대한 유한요소법 적용에 관한 연구
A Study on Application of Finite Element Method to the Impact test for the Safety of the Splash Guard of a CNC Machine Tool 원문보기

한국생산제조시스템학회지 = Journal of the Korean Society of Manufacturing Technology Engineers, v.22 no.5, 2013년, pp.782 - 788

김태원 (Research Center, Hyundai WIA) , 최진우 (Research Center, Hyundai WIA)

Abstract ▼ AI-Helper

This study addresses the issue of safety of the splash guard of a computer numerical control (CNC) machine tool at the design stage. As an impact test for evaluating safety requirements such as strength under the safety regulation is an expensive and iterative task, it is necessary to develop a new method to minimize the task of the impact test for development of the machine tool. In this study, explicit finite element method was adopted for replacement of the impact test of the splash guard of a machine tool at the design stage. A finite element model was developed for implementing the impact test on an actual vertical CNC lathe and then produced the analysis including plastic strain and deformation to enable the safety of its splash guard to be determined. The analysis results demonstrated that the finite element method can be applied to safety evaluation for design of the splash guard of a CNC machine tool.

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문제 정의

However, little research has been performed on safety issues^[7]. In this study, research was carried out on the issue of the safety of a splash guard and focused on identification of a new method to be used for evaluation of the safety strength at the design stage.
This study addresses the issue on evaluation of the safety of the splash guard of a machine tool at the design stage. It is necessary to develop a new method to replace the impact test, for the safety issue, whose procedure is defined, especially, by the European Standard.

가설 설정

1) The kinetic energy of the projectile of the impact test was absorbed into the splash guard as strain energy (internal energy). The total energy which is the sum of the kinetic and strain energies remained nearly constant following energy conservation.
2) The strain and the deformation of the door of the splash guard were usable to determination of through-crack and loosening as the criteria of its safety.

제안 방법

A method needs to be developed to evaluate the safety strength of a splash guard at the design stage. The actual impact test takes much time and cost and, in addition, requires an actual test object.
Details of the impact test were determined based on the diameter of the chuck and its tangential velocity. They determined the projectile size, speed, and, therefore, the impact energy.
3 mm panel of cold rolled carbon steel (KS D 3512: SCP1). Especially, the door was evaluated with the impact test in this study.
In this study, a new method was used to replace the impact test. It was explicit finite element method (FEM) using the commercial FEM tool, ABAQUS/Explicit.
In this study, explicit finite element method was adapted to replacement of the impact test of a machine tool at the design stage. The impact test was implemented into the finite element model developed in this study.
In this study, finite element method was adapted as a new method for the impact test. It was applied to a small turning center (CNC lathe).
The safety criteria are defined for the impact test. Posterior to the projectile impact, examination is carried out to identify any damage to the test object, the splash guard in this study. The damage can be classified generally into the three mechanical failures of buckling, crack, and loosening.
3) An actual experiment of the impact test needs to be carried out for verification and validation of the FE simulation. The experiment may be able to determine replacement of the actual test with the FEA leading to a great reduction in time and cost.

대상 데이터

1 shows the impact test of the ES. It is composed of a gas chamber, a projectile, a barrel, and a test object shown in Fig. 1(a). The chamber filled of high pressurized air shoots the projectile through the barrel to the test object, which is, in this study, the splash guard of a small turning center.
However, a fine mesh is generated at the impact area to express the large deformation with a great strain. The element size was 5 mm. Accordingly, the whole FE model had 142,284 elements including solid elements and 101,534 nodes in total.
The glass compound is composed of a reinforced glass of 5.0 mm thickness and a polycarbonate sheet of 9.5 mm to absorb the impact energy. The glass compound secures a sufficient strength against the impact.
Table 1 presents the materials and their properties used for the components and thus for FEA. The splash guard is made of cold rolled carbon steel (KS D 3512: SCP1) and the glass compound is of the polycarbonate and the reinforced glass. Other structural components such as brackets are of the structural steel with the material properties in Table 1.

이론/모형

Analysis was carried out based on the FE model. The time increment for the FEA was 0.
In this study, a new method was used to replace the impact test. It was explicit finite element method (FEM) using the commercial FEM tool, ABAQUS/Explicit. This method has been widely used for evaluation of crash or stamping with high speed dynamic material behavior^[9-11].
4 shows the plastic stress-strain curve of cold rolled carbon steel (KS D 3512: SCP1) obtained with tensile tests^[15]. It was used for the explicit finite element analysis (FEA). Its ultimate tensile strength is 390 MPa at the plastic strain of 0.
In this study, explicit finite element method was adapted to replacement of the impact test of a machine tool at the design stage. The impact test was implemented into the finite element model developed in this study. The FEA result, such as plastic strain and deformation, helped to evaluate the strength of the door against a through crack and loosening.
A finite element (FE) model was developed for analysis of the safety strength of the splash guard of the machine tool. The result from the finite element analysis (FEA) was used to evaluate the safety strength at the design stage.

후속연구

9～13 that they will lead to a good agreement because of a relatively simple collision. The experiment will be used to verify replacement of the actual impact test with the explicit FEA and thus it can negate manufacturing of the actual splash guard with great time and cost.

참고문헌 (15)

Worker's compensation board of British Columbia 2006, Safeguarding Machinery and Equipment; General Requirements, Worker's compensation board of British Columbia (http://www.worksafebc.com).
EN12415 2002, Safety of machine tools - Small numerically controlled machines and turning centres, European Committee for Standardization.
Jeong, Y. H., Min, B. K., Cho, D. W., Lee S. J., 2010, Motor Current Prediction of a Machine Tool Feed Drive Using a Component-Based Simulation Model, IJPEM, 11:4 597-606.
Choi, J. W., 2012, Mechatronic analysis for feeding a structure of a machine tool using multi-body dynamics, KSMTE, 21:5 691-696.

원문보기 상세보기
Lee, C. H., Choi, J. W., 2013, Evaluation of Thermal Characteristics of a Direct-Connection Spindle Using Finite Element Co-Analysis, KSMTE, 22:2 228-234.

원문보기 상세보기
Kim, T. W., Choi, J. W., 2013, Evaluation of Thermal Characteristics for a Feeding Axis of Machine Tools Using Finite Element Analysis, KSMTE, 22:3 380-387.

원문보기 상세보기
HEMA, 2011, Machine Safety Window; Impact Test, HEMA,, Germany (http://www.hema-schutz.de)
Hyundai WIA, 2011, LV500R;Vertical Turning Center (Catalog), Hyundai WIA, South Korea (www.wiamachine. co.kr).
Lee, C. H., Choi, J. W., 1987, Crash Simulation of Bumpers, Computers & Structures, 26:5 741-747.

상세보기
Iqbal, M. A., Rai, S., Sadique, M. R., Bhargava, P., 2012, Numerical Simulation of Aircraft Crash on Nuclear Containment Structure, Computers & Structures, 243 321-335.
Azaouzia, M., Lebaalb, N., Rauchsa, G., Belouettara, S., 2012, Optimal design of multi-step stamping tools based on response surface method, Simulation Modeling Practice and Theory, 24 1-14.

상세보기
Wisniewski, K., Kolakowski, P. 2003, The effect of selected parameters on ship collision results by dynamic FE simulations Finite Elements in Analysis and Design, 39:10 985-1006.

상세보기
Dirschmid, F., Hooputra, H., Mader, H.U., Werner, H. 2005, Migration of Crash Simulation Software at BMW ABAQUS Users' Conference
ABAQUS, 2012, ABAQUS Manual: Version 6.12, Dassault Systems.
Hyundai WIA, 2011, Tensile test of the cold rolled carbon steel (KS D 3512: SCP1) in sheet (Internal Material Test Report), Hyundai WIA, South Korea.

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CNC 공작기계 스프레쉬 가드의 안전성을 위한 충격 시험에 대한 유한요소법 적용에 관한 연구
A Study on Application of Finite Element Method to the Impact test for the Safety of the Splash Guard of a CNC Machine Tool 원문보기

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CNC 공작기계 스프레쉬 가드의 안전성을 위한 충격 시험에 대한 유한요소법 적용에 관한 연구 A Study on Application of Finite Element Method to the Impact test for the Safety of the Splash Guard of a CNC Machine Tool 원문보기

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CNC 공작기계 스프레쉬 가드의 안전성을 위한 충격 시험에 대한 유한요소법 적용에 관한 연구
A Study on Application of Finite Element Method to the Impact test for the Safety of the Splash Guard of a CNC Machine Tool 원문보기

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