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Effect of spatial moving structure and topology optimization of the CNC turning machine tools

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Abstract

In order to enhance the accuracy and productivity of CNC machine tools, the finite element method (FEM) is utilized for analyzing machining operations and machine tool structures. Through this approach, it becomes possible to assess and reduce machining errors, thereby improving the precision of machined parts. Additionally, by subjecting machine tool components to the analysis of stress and deformations under real operating conditions, the overall performance and lifespan of the machine tool structures can be augmented. This study focuses on the implementation of finite element methods for the analysis and optimization of CNC machine tool operations and structure. In this study, a virtual model of the Good Way CNC turning machine was used to study the machine’s behavior. The first three vibrational modes analyzed through a modal analysis were 108.2 Hz, 133.4 Hz, and 191.7 Hz, which were experimentally validated using modal tests. The design precision was supported by the harmonic response. For an applied external load of 500 N on the head chuck, the tool turret's transient response was established through transient analysis at 0.4 s. However, after the static analysis, the maximum deformation of the machine at the same external applied load on the tool turret was upheld at 7.6 μm. The spatial position analysis rectified the modal performance of the machine at a variety of set working positions. As the principal cause of rigidity originates from the base of the machine, three sets of ground support combinations were claimed to test the machine's rigidity. After the topology optimization analysis was achieved, a better-optimized version of the design was suggested. The old and new models were compared, and an increase of 1.5% in the first three modal frequencies was observed.

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Abbreviations

m :

mass of the system (kg)

k :

stiffness coefficient (N/m)

c :

damping coefficient (Ns/m)

ω :

angular frequency (rad/s)

f(t):

applied force as a function of time (N)

u(t):

displacement as a function of time (m)

x(f):

frequency domain representation of displacement (m/Hz)

Φ:

mode shape vector

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Acknowledgements

The authors are indebted to the National Science and Technology Council (Grant numbers: 111-2221-E-150-024-MY2 and 111-2622-E-150-009).

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Authors and Affiliations

  1. Department of Mechanical and Computer-Aided Engineering, National Formosa University, Huwei Township, Yunlin County, 632, Taiwan, Republic of China

    Tzu-Chi Chan, Sabbella Veera Venkata Satyanarayana Reddy & Bedanta Roy

  2. Department of Power Mechanical Engineering, National Formosa University, Huwei Township, Yunlin County, 632, Taiwan, Republic of China

    Aman Ullah

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  1. Tzu-Chi Chan
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  2. Sabbella Veera Venkata Satyanarayana Reddy
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  3. Aman Ullah
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Contributions

Experiment: S. Reddy. Analysis: Aman U and S. Reddy. Methodology: T.-C. Chan and S. Reddy. Validation: S. Reddy. Original draft preparation: Aman U, S. Reddy, and B. Roy. Supervision: T.-C. Chan.

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Correspondence to Aman Ullah.

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Chan, TC., Reddy, S.V.V.S., Ullah, A. et al. Effect of spatial moving structure and topology optimization of the CNC turning machine tools. Int J Adv Manuf Technol 129, 2969–2987 (2023). https://doi.org/10.1007/s00170-023-12500-z

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