Optimal placement and tuning of multiple-mass-dampers within a combined topology optimization method

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The dynamic behavior is a deciding factor in modern high-performance machine tools. To improve the dynamic behavior already during the development phase, structural optimization methods can be used. Especially by using topology optimization, the stiffness-to-mass ratio of frame components, with respect to their Eigen frequencies for example, can be optimized. Mainly for existing machines, dynamic auxiliary systems like tuned mass dampers (TMD) can be used to improve the dynamic compliance by damping specific vibration modes. However, those systems are rarely used in the development phase and are often considered to be problem-solvers.The overall goal of the research project is to develop a new optimization method to reduce the dynamic compliance of machine tools, combining topology optimization and an optimal layout of distributed TMD systems. During the first funding period, an automated optimal positioning and new analytic tuning method for multi-mass dampers was developed and experimentally verified. Furthermore, a framework was developed to be able to realize the combined optimization approach.The second phase of the research project focuses on the implementation and testing of coupling mechanisms for topology optimization and damper tuning as well as on the practical verification of the combined approach using additive manufacturing methods, which allow the manufacturing of light-weight structures with integrated mass dampers within a single part. To this end, manufacturing restrictions need to be considered during the optimization, the additively manufactured damper masses need to be parametrizable and the optimization results must be converted into a production-oriented data format. The combined optimization method will be experimentally verified using an SLM demonstrator, finally evaluating its performance.