Skip to main content
SpringerLink
Log in

A CAD/CAE-integrated structural design framework for machine tools

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In this paper, a novel integrated framework for design and optimization of a machine tool structure is presented, which can greatly improve the design quality and efficiency by combining knowledge-based design and multi-stage optimization with the CAD/CAE integration technique. To realize this framework, a topology architecture model has been developed to integrate the configuration design and geometric modeling knowledge as well as the static and dynamic evaluation knowledge of machine tools with a specific topology architecture type; an analysis feature model is proposed for the integration between commercial CAD and CAE software, in which analysis features can be automatically converted to a script code for finite element analysis (FEA) through feature mapping. Based on the topology architecture model and feature-based CAD/CAE integration methodology, a two-stage design optimization process is proposed to perform the conceptual structural design of machine tools. In the first stage, the principal parameters which critically affect the performance of an entire machine are determined; then, the static and dynamic stiffness matching designs are performed to obtain the reasonable stiffness and weight of each structural part and functional component based on the stiffness model and dynamic model. In the second stage, the arrangement of ribs is determined by inferring the design knowledge; FEA is used to evaluate the performances of structural parts, and the response surface method (RSM) is applied to optimize the structural parameters to approach the stiffness and mass close to the allocated values obtained from the first stage. Re-design of a four-axis horizontal machining center with a box-in-box architecture was carried out to illustrate the design procedure in detail and to verify the feasibility and efficacy of the proposed framework. By applying the proposed framework, the total weight of the entire machine is minimized while sufficient stiffness is maintained. The results also show that the proposed framework facilitates the conceptual structural design and optimization process of machine tools.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Bohez E (2002) Five-axis milling machine tool kinematic chain design and analysis. International Journal of Machine Tools & Manufacture 42(4):505–520

    Article  Google Scholar 

  2. Huo D, Cheng K, Wardle F (2010) Design of a five-axis ultra-precision micro-milling machine—UltraMill. Part 1: holistic design approach, design considerations and specifications. Int J Adv Manuf Technol 47(9–12):867–877

    Article  Google Scholar 

  3. 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):73–85

    Article  Google Scholar 

  4. Wu BC, Young GS, Huang TY (2000) Application of a two-level optimization process to conceptual structural design of a machine tool. International Journal of Machine Tools & Manufacture 40(6):783–794

    Article  Google Scholar 

  5. Chen W, Luo X, Su H, Wardle F (2016) An integrated system for ultra-precision machine tool design in conceptual and fundamental design stage. Int J Adv Manuf Technol 84(5–8):1177–1183

    Google Scholar 

  6. Hunter R, Vizán A, Pérez J, Ríos J (2005) Knowledge model as an integral way to reuse the knowledge for fixture design process. J Mater Process Technol 164–165(20):1510–1518

    Article  Google Scholar 

  7. Nacsa J, Bueno R, Alzaga A, Kovács LG (2005) Knowledge management support for machine tool designers using expert enablers. Int J Comput Integr Manuf 18(7):561–571

    Article  Google Scholar 

  8. Chen X, Gao S, Guo S, Bai J (2012) A flexible assembly retrieval approach for model reuse. Comput Aided Des 44(6):554–574

    Article  Google Scholar 

  9. Miled AB (2014) Reusing knowledge based on ontology and organizational model. Procedia Computer Science 35:766–775

    Article  Google Scholar 

  10. Guo Y, Hu J, Peng Y (2012) A CBR system for injection mould design based on ontology: a case study. Comput Aided Des 44(6):496–508

    Article  Google Scholar 

  11. Baxter D, Gao J, Case K, Harding J, Young B, Cochrane S, Dani S (2007) An engineering design knowledge reuse methodology using process modelling. Res Eng Des 18(1):37–48

    Article  Google Scholar 

  12. Li BM, Xie SQ, Xu X (2011) Recent development of knowledge-based systems, methods and tools for one-of-a-kind production. Knowl-Based Syst 24(7):1108–1119

    Article  Google Scholar 

  13. Lee IH, Cha JH, Park MW, Kim JJ (2003) An integrated inference architecture for machine tools design involving complex knowledge. Int J Adv Manuf Technol 22(22):321–328

    Article  Google Scholar 

  14. Park MW, Sohn YT (2006) Development of integrated design system for structural design of machine tools. In: ElMaraghy H, ElMaraghy W (eds) Advances in design, 2006. Springer, London, pp. 547–558

    Chapter  Google Scholar 

  15. Liu L, Caldwell BS, Wang H, Li Y (2014) A knowledge-centric CNC machine tool design and development process management framework. Int J Prod Res 52(20):6033–6051

    Article  Google Scholar 

  16. Myon-Woong CJH, Park JH, Kang M (1999) Development of an intelligent design system for embodiment design of machine tools. CIRP Ann Manuf Technol 48(1):329–332

    Article  Google Scholar 

  17. Aleixos N, Company P, Contero M (2004) Integrated modeling with top-down approach in subsidiary industries. Comput Ind 53(1):97–116

    Article  Google Scholar 

  18. Wu J, Wang J, Wang L, Li T, You Z (2009) Study on the stiffness of a 5-DOF hybrid machine tool with actuation redundancy. Mechanism & Machine Theory 44(2):289–305

    Article  MATH  Google Scholar 

  19. Portman VT, Shneor Y, Chapsky VS, Shapiro A (2015) Form-shaping function theory expansion: stiffness model of multi-axis machines. Int J Adv Manuf Technol 76(5–8):1063–1078

    Article  Google Scholar 

  20. Peng F, Yan R, Chen W, Yang J, Li B (2012) Anisotropic force ellipsoid based multi-axis motion optimization of machine tools. Chinese Journal of Mechanical Engineering 25(5):960–967

    Article  Google Scholar 

  21. Yan R (2012) Closed-loop stiffness modeling and stiffness index analysis for multi-axis machining system. Journal of Mechanical Engineering 48(1):177–184 In Chinese

    Article  MathSciNet  Google Scholar 

  22. Yan R, Peng F, Li B (2008) A method of general stiffness modeling for multi-axis machine tool. In: Intelligent Robotics & Applications, First International Conference, Wuhan, China. pp 1013–1021

  23. Huang TY, Lee JJ (2001) On obtaining machine tool stiffness by CAE techniques. International Journal of Machine Tools & Manufacture 41(8):1149–1163

    Article  Google Scholar 

  24. Shi Y, Zhao X, Zhang H, Nie Y, Zhang D (2016) A new top-down design method for the stiffness of precision machine tools. Int J Adv Manuf Technol 83(9):1887–1904

    Article  Google Scholar 

  25. Yu Z, Nakamoto K, Ishida T, Takeuchi Y (2010) Interactive design-assistance system of machine tool structure in conceptual and fundamental design stage. Int J Autom Technol 4(3):303–311

    Article  Google Scholar 

  26. Shore P, Morantz P, Luo X, Tonnellier X, Collins R, Roberts A, May-Miller R, Read R (2005) Big OptiX ultra precision grinding/measuring system. In: Optical fabrication, testing, and metrology II: Proceedings of SPIE

  27. 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):335–343

    Article  Google Scholar 

  28. Lin CY, Hung JP, Lo TL (2010) Effect of preload of linear guides on dynamic characteristics of a vertical column–spindle system. Int J Mach Tools Manuf 50(8):741–746

    Article  Google Scholar 

  29. Yigit AS, Ulsoy AG (2002) Dynamic stiffness evaluation for reconfigurable machine tools including weakly non-linear joint characteristics. Proc Inst Mech Eng B J Eng Manuf 216(1):87–101

    Article  Google Scholar 

  30. Gujarathi G, Ma Y-S (2011) Parametric CAD/CAE integration using a common data model. J Manuf Syst 30(3):118–132

    Article  Google Scholar 

  31. Wang YY, Huang T, Zhao XM, Mei JP, Chetwyn DG, Hu SJ (2006) Finite element analysis and comparison of two hybrid robots-the tricept and the trivariant. In: Intelligent robots and systems. IEEE, pp 490–495

  32. Xu B, Chen N (2009) An integrated method of CAD, CAE and multi-objective optimization. In: International Conference on Computer-Aided Industrial Design & Conceptual Design. CAID & CD, pp 1010–1014

  33. Park HS, Dang XP (2010) Structural optimization based on CAD–CAE integration and metamodeling techniques. Comput Aided Des 42(10):889–902

    Article  Google Scholar 

  34. Dang XP (2014) General frameworks for optimization of plastic injection molding process parameters. Simul Model Pract Theory 41:15–27

    Article  Google Scholar 

  35. Wang D, Hu F, Ma Z, Wu Z, Zhang W (2014) A CAD/CAE integrated framework for structural design optimization using sequential approximation optimization. Adv Eng Softw 76:56–68

    Article  Google Scholar 

  36. Yin CG, Ma YS (2012) Parametric feature constraint modeling and mapping in product development. Adv Eng Inform 26(3):539–552

    Article  MathSciNet  Google Scholar 

  37. Li WD, Ong SK, Fuh JYH, Wong YS, Lu YQ, Nee AYC (2004) Feature-based design in a distributed and collaborative environment. Comput Aided Des 36(9):775–797

    Article  Google Scholar 

  38. Aifaoui N, Deneux D, Benamara A, Soenen R, (2002) Dogui A Mechanical analysis process modeling based on analysis features. In: Systems, man and cybernetics, IEEE International Conference on, 2002. IEEE, vol. 3

  39. Gao S, Zhao W, Lin H, Yang F, Chen X (2010) Feature suppression based CAD mesh model simplification. Comput Aided Des 42(12):1178–1188

    Article  Google Scholar 

  40. Lee SH (2005) A CAD-CAE integration approach using feature-based multi-resolution and multi-abstraction modelling techniques. Comput Aided Des 37(9):941–955

    Article  Google Scholar 

  41. Xia Z, Wang Q, Wang Y, Yu C (2015) A CAD/CAE incorporate software framework using a unified representation architecture. Adv Eng Softw 87:68–85

    Article  Google Scholar 

  42. Beards C (1992) Damping in structural joints. The Shock and Vibration Digest 24(7):3–7

    Article  Google Scholar 

  43. Mäntylä M (1990) A modeling system for top-down design of assembled products. IBM J Res Dev 34(5):636–659

    Article  Google Scholar 

  44. Park GJ (2007) Analytic methods for design practice. Springer London, London

    MATH  Google Scholar 

  45. Gao S, Zhang S, Chen X, Yang Y (2013) A framework for collaborative top-down assembly design. Comput Ind 64(8):967–983

    Article  Google Scholar 

  46. Mun D, Hwang J, Han S (2009) Protection of intellectual property based on a skeleton model in product design collaboration. Comput Aided Des 41(9):641–648

    Article  Google Scholar 

  47. Park HW, Park YB, Liang SY (2011) Multi-procedure design optimization and analysis of mesoscale machine tools. Int J Adv Manuf Technol 56(1–4):1–12

    Article  Google Scholar 

  48. Xue L (2014) Mass matching design method for structural components of precession horizontal machining center. Tianjin University, Dissertation In Chinese

    Google Scholar 

  49. Guo T, Li L, Cai L, Zhao Y (2012) Alternative method for identification of the dynamic properties of bolted joints. J Mech Sci Technol 26(10):3017–3027

    Article  Google Scholar 

  50. 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(5–8):1225–1242

    Article  Google Scholar 

  51. Zuo W (2013) An object-oriented graphics interface design and optimization software for cross-sectional shape of automobile body. Adv Eng Softw 64:1–10

    Article  Google Scholar 

  52. Patzák B, Rypl D (2012) Object-oriented, parallel finite element framework with dynamic load balancing. Adv Eng Softw 47(1):35–50

    Article  Google Scholar 

  53. Lee HJ, Lee JW, Lee JO (2009) Development of web services-based multidisciplinary design optimization framework. Adv Eng Softw 40(3):176–183

    Article  Google Scholar 

  54. Hung JP (2009) Load effect on the vibration characteristics of a stage with rolling guides. J Mech Sci Technol 23(1):89–99

    Article  Google Scholar 

  55. Hung JP, Lai YL, Lin CY, Lo TL (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):731–739

    Article  Google Scholar 

  56. Niu W, Wang P, Shen Y, Gao W, Wang L A (2011) Feature-based CAD-CAE integrated approach of machine tool and its implementation. In: Advanced materials research. Trans Tech Publications, pp 54–58

  57. Ma Y, Niu W, Luo Z, Yin F, Huang T (2016) Static and dynamic performance evaluation of a 3-DOF spindle head using CAD-CAE integration methodology. Robot Comput Integr Manuf 41:1–12

    Article  Google Scholar 

  58. Deng YM, Lam Y, Tor SB, Britton G (2002) A CAD-CAE integrated injection molding design system. Eng Comput 18(1):80–92

    Article  MATH  Google Scholar 

  59. Box GE, Behnken DW (1960) Some new three level designs for the study of quantitative variables. Technometrics 2(4):455–475

    Article  MathSciNet  MATH  Google Scholar 

  60. 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):1053–1065

    Google Scholar 

  61. Montgomery DC (2008) Design and analysis of experiments. John Wiley & Sons, Hoboken

    Google Scholar 

  62. Zulaika JJ, Campa FJ, de Lacalle LL (2011) An integrated process–machine approach for designing productive and lightweight milling machines. Int J Mach Tools Manuf 51(7):591–604

    Article  Google Scholar 

  63. Bamberger E (2000) Principles of rapid machine design. Dissertation, Massachusetts Institute of Technology

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Key Laboratory of Mechanism Theory and Equipment Design of The State Education Ministry, Tianjin University, Tianjin, 300350, China

    Junqiang Wang, Wentie Niu, Yue Ma, Lingjun Xue & Dawei Zhang

  2. Shenji Group Kunming Machine Tool Company Limited, Kunming, 650203, China

    Huaying Cun

  3. Beijing Machine Tool Research Institute, Beijing, 100102, China

    Yingxin Nie

Authors
  1. Junqiang Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Wentie Niu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yue Ma
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Lingjun Xue
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Huaying Cun
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Yingxin Nie
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Dawei Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Wentie Niu.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Wang, J., Niu, W., Ma, Y. et al. A CAD/CAE-integrated structural design framework for machine tools. Int J Adv Manuf Technol 91, 545–568 (2017). https://doi.org/10.1007/s00170-016-9721-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-016-9721-y

Keywords

Search

Navigation