Stiffness in Precision Machine Design

BJ Furman 11OCT97

Stiffness in Precision Machine Design

One of the most important general criteria of machine design. (E.

Rivin, Mechanical Design of Robots, McGraw-Hill, 1988.)

Important in the minimization of deflection and maximization of natural frequencies

Need to understand the sources of structural compliance to design knowledgeably, be able to identify weak points, calculate compliances, and improve existing structural designs.

Compliance is 1/stiffness F=kX --> X=cF

Factors influencing stiffness:

Material modulus Structural configuration of load-transmitting components

bars, plates, rods, shells

Mode of loading Contact deformation between mating parts Type of actuator and its design

Mode of Loading

Types of structural loading:

tension, compression, bending, torsion

Members in tension and compression have smaller deflections (hence are stiffer) for similar loading intensities. Consider a rod of length L, cross-sectional area, A and loading by self-weight, W or force, P:

in tension:
p=PL/EA w=WL/2EA w=WL3/8EI w=5WL3/384EI

cantilevered:
p=PL3/3EI

simply supported:
p=PL3/48EI

in torsion:
p=(TL/GJ)(d/2) = PLd2/4GJ

For a round cross-section of diameter d

A=d2/4, I=d4/64, I/A=d2/16

Mode of Loading, cont.

Comparing deflections between loading modes:

Cantilever to uniaxial:
Due to P=16/3(L/d)2 Due to self-weight=4(L/d)2 Due to self-weight=5/12(L/d)2

Simply supported to uniaxial:

Due to P=1/3(L/d)2

Torsion to uniaxial:
5
10000

Cantilevered

Def. Ratio to Tensile

1000

Simply supported
100

10

Torsion

1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

0 .1

L/d

Influence of Cross-Sectional Shape

Try to maximize the strength to weight ratio of structural members. Ex. Comparison of bending stiffness and weight of round vs. square hollow sections.

For the same weight, rectangular sections are stiffer Internal cross sectional area larger too
Important where cables etc. may pass through

Minimizing Deflection Under Self-Weight

Airy points

The support locations that maintains verticality of the end faces of simply supported rectangular beam
Most important for end standards (like a meter bar)

Bessel points

http://www.tesabs.ch/Catalog/En/CatTESAEn/html/CatTESAEn_17.html

The support locations that minimize deflection of the neutral axis of a rectangular beam
Use to support straightedges

http://www.tesabs.ch/Catalog/En/CatTESAEn/html/CatTESAEn_17.html

Contact (Joint) Stiffness

The actual area of contact for two mating surfaces is typically quite small:

Because of surface roughness (micro asperities in contact) and/or Because of geometry as in the case of nominally curved surfaces Hertzian contact stresses in peaks of asperities lead to their flattening. Ex. Typical sliding guideways in machine tools (about 10 micron/Mpa)

Contact deformations can therefore be substantial

Results in decreased stiffness Theoretical contact modeling is quite complex

Reliable design information from experimental data. (p. 373)

Contact deformation =(p)p, where depends on contact pressure and type and type of surfaces in contact.

Smoother, flatter surfaces have smaller , hence are stiffer. Higher contact pressure results in higher stiffness

Contact (joint) Stiffness, cont.

See Slocums treatment of bolted joints, p. 366-381.

Good guidelines for determining the required preload and bolt size for a joint on p. 376. Adhesives can enhance stiffness of bolted joints by filling voids. Will also increase damping and shear strength Filling around a joint to help lock in place Good way to create precisely mating surfaces
Bearings Beds Diffraction gratings

Adhesive joints

Potting

Replication

Enhancement of Stiffness Through Preload

Preloading can enhance stiffness

Belt drive example from Rivin Ball bearings in precision applications Axially load to enhance bending stiffness

Structural Design

The minimum structure required for 3D stiffness is a structurally closed polyhedral shell (enclosed solid formed by plane faces) or bar equivalent structure.

Exactly constrained Tetrahedron is the simplest 3D stiff bar structure

Fixing any three of its apexes, the other will be stiff to any applied force

Other bar 3D bar structures obey:

B=3j-6

B=no. of bars J=no. of joints, J4

Each face is 2D stiff

A sheet A bar structure with:

B=2J-3

B=no. of bars J=no. of joints, J3

Structural Design, cont.

Examples from Blanding

Polyhedral bar structures Sheet structures Tube structures

Need closed (2D stiff ends)

B=N-3

Points on a structure that are stiff to loads comprise the locus of rigidity of the structure.

For bar structures, the joints. For sheet structures, the edges. Areas of a structure far from the locus of rigidity are susceptible to transverse vibrations.
The center of sheets

Any loadings should be applied to points on the locus of rigidity.

Add holes or ribs

Structural Design, cont.

Design your structure for 3D stiffness:

1. Identify all the structurally significant points. 2. Design a 3D stiff core structure that fits within the envelope of the proposed machine, preferably no less than 25%. 3. Use the process of 3D joint addition to extend the locus of rigidity to all the structurally significant points. 4. Build a cardboard model and test it for rigidity. Example from Blanding p. 94

Strive for symmetry in your designs.