Performance-balanced composition design: High-performance resin mineral composites and their lightweight applications in machine tools

Abstract

With the increasing demands for dynamic stability and thermal deformation control in high-precision CNC machine tools, resin mineral composites have emerged as a critical alternative to traditional cast iron due to their high damping capacity, low coefficient of thermal expansion, and favorable design flexibility. This study systematically investigates the influence mechanisms of resin type, curing agent category, aggregate gradation, and fiber type on the static/dynamic mechanical properties and thermal stability of the composites. Through static compression tests, dynamic damping measurements, and thermal performance experiments, the intrinsic relationships between composite composition and properties were elucidated. Combining experimental testing and microstructural analysis, the material formulation was optimized. It was found that a binder content of 14% represents the optimal balance, achieving high stiffness (43.32 GPa), high strength (96.4 MPa), and low thermal expansion (1.07 × 10⁻⁵/°C), albeit at the cost of approximately 25% reduction in damping performance. Based on the optimized parameters, finite element simulation and lightweight structural design were further conducted for the machine tool bed. The results demonstrate that, compared to a cast iron bed, the resin mineral composite bed exhibits a 49.1% reduction in deformation and increased first three natural frequencies. Moreover, the lightweight design achieved a 24.6% mass reduction while maintaining excellent static and dynamic stiffness. This research provides theoretical and experimental support for the practical application of resin mineral composites in machine tools.