Dynamic finite element analysis of rotor-shaft fastening into a heavy precise lathe

The results of finite element analysis of large machined rotor fastened into heavy precise lathe are reported. Many design changes are simulated to improve the dynamic rigidity of the machining. Three radial eigenmodes detrimental to the accuracy were revealed: rotor-stock bending at 17.7 Hz (“half-wave”), rotor-lathe bending at 36.1 Hz (“full-wave”), and “support rocking” at 68.1 Hz. The frequency response functions and dynamic rigidities were evaluated. Three compliance issues were revealed: angular flexibility of the spindle console, low stiffness of the lathe bed (with boots), and an excessively slender tailstock. It is proposed to transform the spindle chuck into a table with additional hydrostatic backing, fill the bed cavities with concrete, and redesign the tailstock as a counter-spindle unit. This will decrease the amplitude of the main rotor resonance by 6.3 times and upshift the frequency near two-fold from 17.7 to 35 Hz. The renovated lathe should be able to machine a rotor without a lunette system or overriding the main resonant frequency.