Reconfiguring machine tool behavior via smart building block systems

The reconfigurability of manufacturing systems is conventionally increased by utilizing concepts of modularization and platforms. At this moment, the actual reconfigurability is often limited to a priori designed reconfiguration variants for the production within single part families. There is only a little research on reconfiguring the mechanical behavior of machine tool frames. This paper presents an innovative approach for reconfiguring the mechanical behavior based on smart building block systems. Topologically optimized polyhedral building blocks are mechanically bolted to form different machine tool frame configurations. A high grade of modularization allows for the assembly of individualized topologies for different manufacturing scenarios "as needed when needed". The increase in reconfigurability results from the high geometric flexibility of the proposed building block system. However, successful implementation relies on quick and robust simulation approaches for calculating the machine tool frame characteristics before the actual assembly process. Within this paper, a time-efficient approach based on the sub-structuring methodology is utilized. The presented approach consists of forming superelements by performing a GUYAN reduction on the building blocks to extract the stiffness behavior. A Component Mode Synthesis is used to extract modal information. The ANSYS Parametric Design Language is then used to automatically couple the modules according to a customized descriptive machine tool language. A simple joint model is implemented and experimentally fitted with a two-block configuration. The two-block configuration is then extrapolated to a full machine tool frame portal. An example of changing the modal characteristics of this machine tool frame portal is presented in the form of numerical results.