Advertisement

Structural dynamic design optimization and experimental verification of a machine tool

  • Lei Shen
  • Xiaohong DingEmail author
  • Tianjian Li
  • Xiangzhi Kong
  • Xiaohu Dong
ORIGINAL ARTICLE
  • 159 Downloads

Abstract

Structural dynamic performance of a machine tool greatly affects machining precision and productivity. One effective approach in improving the dynamic performance is by applying topology design optimization to the machine tool structure. However, traditional topology optimization method is hard to implement and does not provide a clear stiffener layout. Furthermore, the topology optimization of certain components does not signify the performance improvement of a holistic machine tool. This paper suggests a new structural dynamic design optimization method for the holistic machine tool. The Adaptive Growth Method which is based on the growth mechanism of natural branch systems is adopted to design the inner stiffener layout of structures, and an optimization strategy for the holistic machine tool utilizing dynamic sensitivity analysis is studied. Both components and contact parts are considered. The dynamic sensitivities of the components are analyzed based on modal test data, and help to determine which components need to be optimized. Then, the headstock, column, and bed are optimized, and the weak contact stiffness is improved. The FEA (finite element analysis) results of an optimized machine tool show that the TCP (tool center point) harmonic displacement is decreased distinctly. To validate the effectiveness of the suggested method, an experiment of the manufactured machine tool structure is conducted, and the experimental results had shown great improvements in the holistic machine tool.

Keywords

Machine tool structure Dynamic performance Topology optimization Dynamic sensitivity analysis Modal test 

Notes

Funding information

This research is supported by the National Natural Science Foundation of China (Grant No. 51405300) and the Science and Technology Major Special Project of China (Grant No. 2019zx04005-001-010).

References

  1. 1.
    Möhring H-C, Brecher C, Abele E, Fleischer J, Bleicher F (2015) Materials in machine tool structures. CIRP Ann Manuf Technol 64(2):725–748CrossRefGoogle Scholar
  2. 2.
    Huo D, Cheng K, Wardle F (2010) A holistic integrated dynamic design and modelling approach applied to the development of ultraprecision micro-milling machines. Int J Mach Tools Manuf 50(4):335–343CrossRefGoogle Scholar
  3. 3.
    Liu S (2014) Multi-objective optimization design method for the machine tool’s structural parts based on computer-aided engineering. Int J Adv Manuf Technol 78(5–8):1053–1065Google Scholar
  4. 4.
    Shi Y, Zhao X, Zhang H, Nie Y, Zhang D (2015) A new top-down design method for the stiffness of precision machine tools. Int J Adv Manuf Technol 83(9–12):1887–1904Google Scholar
  5. 5.
    Bendsøe MP, Kikuchi N (1988) Generating optimal topologies in structural design using a homogenization method. Comput Methods Appl Mech Eng 71(2):197–224MathSciNetCrossRefGoogle Scholar
  6. 6.
    Bendsøe MP, Sigmund O (1999) Material interpolation schemes in topology optimization. Arch Appl Mech 69(9):635–654zbMATHGoogle Scholar
  7. 7.
    Drude N, Meier L, Hoffmann H, Scheurle J (2009) Model based strategies for an optimised ribbing design of large forming tools. Prod Eng 3(4):435–440CrossRefGoogle Scholar
  8. 8.
    Yun Q, Niu WT, Wang JQ, Zhang L (2013) Structure design of precision horizontal machining center and multi-objective optimization of large structural components. Adv Mater Res 712–715:1514–1518CrossRefGoogle Scholar
  9. 9.
    Chen TY, Wang CB (2008) Topological and sizing optimization of reinforced ribs for a machining centre. Eng Optim 40(1):33–45CrossRefGoogle Scholar
  10. 10.
    Law M, Altintas Y, Srikantha Phani A (2013) Rapid evaluation and optimization of machine tools with position-dependent stability. Int J Mach Tools Manuf 68:81–90CrossRefGoogle Scholar
  11. 11.
    Dong X, Ding X, Xiong M (2018) Optimal layout of internal stiffeners for three-dimensional box structures based on natural branching phenomena. Eng Optim:1–18.Google Scholar
  12. 12.
    Ding X, Yamazaki K (2004) Stiffener layout design for plate structures by growing and branching tree model (application to vibration-proof design). Struct Multidiscip Optim 26(1):99–110CrossRefGoogle Scholar
  13. 13.
    Ding X, Yamazaki K (2005) Adaptive growth technique of stiffener layout pattern for plate and shell structures to achieve minimum compliance. Eng Optim 37(3):259–276MathSciNetCrossRefGoogle Scholar
  14. 14.
    Ji J, Ding X, Xiong M (2014) Optimal stiffener layout of plate/shell structures by bionic growth method. Comput Struct 135:88–99CrossRefGoogle Scholar
  15. 15.
    Li B, Hong J, Liu Z (2014) Stiffness design of machine tool structures by a biologically inspired topology optimization method. Int J Mach Tools Manuf 84:33–44CrossRefGoogle Scholar
  16. 16.
    Zhang H, Ding X, Dong X, Xiong M (2017) Optimal topology design of internal stiffeners for machine pedestal structures using biological branching phenomena. Struct Multidiscip OptimGoogle Scholar
  17. 17.
    Yan S, Li B, Hong J (2015) Bionic design and verification of high-precision machine tool structures. Int J Adv Manuf Technol 81(1–4):73–85CrossRefGoogle Scholar
  18. 18.
    Wu B-C, Young G-S, Huang T-Y (2000) Application of a two-level optimization process to conceptual structural design of a machine tool. Int J Mach Tools Manuf 40(6):783–794CrossRefGoogle Scholar
  19. 19.
    Wang J, Niu W, Ma Y, Xue L, Cun H, Nie Y, Zhang D (2016) A CAD/CAE-integrated structural design framework for machine tools. Int J Adv Manuf Technol 91(1–4):545–568Google Scholar
  20. 20.
    Li W, Li B, Yang J (2017) Design and dynamic optimization of an ultra-precision micro grinding machine tool for flexible joint blade machining. Int J Adv Manuf Technol 93(9–12):3135–3147CrossRefGoogle Scholar
  21. 21.
    He S, Mao X, Liu X, Luo B, Li B, Peng F (2015) A new approach based on modal mass distribution matrix to identify weak components of machine tool structure. Int J Adv Manuf Technol 83(1–4):193–203Google Scholar
  22. 22.
    Liang Y, Chen W, Sun Y, Luo X, Lu L, Liu H (2013) A mechanical structure-based design method and its implementation on a fly-cutting machine tool design. Int J Adv Manuf Technol 70(9–12):1915–1921Google Scholar
  23. 23.
    Chen W, Liang Y, Sun Y, Huo D, Lu L, Liu H (2013) Design philosophy of an ultra-precision fly cutting machine tool for KDP crystal machining and its implementation on the structure design. Int J Adv Manuf Technol 70(1–4):429–438Google Scholar
  24. 24.
    Li TJ, Ding XH, Cheng K, Wu T (2017) Dynamic optimization method with applications for machine tools based on approximation model. P I Mech Eng C-J Mec 232(11):2009–2022CrossRefGoogle Scholar
  25. 25.
    Zhao L, Chen H, Yao Y, Diao G (2016) A new approach to improving the machining precision based on dynamic sensitivity analysis. Int J Mach Tools Manuf 102:9–21CrossRefGoogle Scholar
  26. 26.
    Zhang GP, Huang YM, Shi WH, Fu WP (2003) Predicting dynamic behaviours of a whole machine tool structure based on computer-aided engineering. Int J Mach Tools Manuf 43(7):699–706CrossRefGoogle Scholar
  27. 27.
    Deng C, Yin G, Fang H, Meng Z (2015) Dynamic characteristics optimization for a whole vertical machining center based on the configuration of joint stiffness. Int J Adv Manuf Technol 76(5):1225–1242CrossRefGoogle Scholar
  28. 28.
    Hung J-P, Lai Y-L, Lin C-Y, Lo T-L (2011) Modeling the machining stability of a vertical milling machine under the influence of the preloaded linear guide. Int J Mach Tools Manuf 51(9):731–739CrossRefGoogle Scholar
  29. 29.
    Hung JP, Lai YL, Luo TL, Su HC (2013) Analysis of the machining stability of a milling machine considering the effect of machine frame structure and spindle bearings: experimental and finite element approaches. Int J Adv Manuf Technol 68(9–12):2393–2405CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  1. 1.School of Mechanical EngineeringUniversity of Shanghai for Science and TechnologyShanghaiChina
  2. 2.Shenyang Machine Tool (Group) Design and Research InstituteShenyangChina

Personalised recommendations