Cross-scale numerical analysis and optimization of machine tool dynamics by integration of particle-filled hollow sphere structures

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Increasing the productivity of machine tools requires higher feed rates. This requires higher accelerations and, due to jerk, leads to broadband excitation of the frame structure, which is reflected in the quality of the workpiece. The necessary reduction of vibration amplitudes can be achieved by passive damping methods without further energy consumption. For climate-neutral production, their use is preferable to active methods. Particle-filled hollow sphere structures (PHS) enable lightweight construction with structure-integrated, locally adapted, passive damping while maintaining a high elastic modulus-to-density ratio. Due to the lack of numerical design methods, the outstanding properties of PHS cannot currently be used specifically in complex structures. The aim of the project is to provide a consistent simulation method that represents the frequency-selective dynamic properties at the micro, meso and macro levels and thus enables macroscopic structural optimization of dynamically highly loaded machine components by manipulating local material properties at the micro level. The damping properties are to be varied in such a way that the resulting damping can be optimized with respect to natural structural frequencies and these frequency-optimized hollow spheres can then be positioned at locations with the best possible damping effect according to the macroscopic vibration shapes.