Finite element analysis and structure optimization of a gantry-type high-precision machine tool.

Area of Science:

• Mechanical Engineering
• Manufacturing Technology
• Computational Mechanics

Background:

• The dynamic, static, and rigid properties of high-precision machine tools are critical for machining efficiency and surface quality.
• Static and dynamic analyses are fundamental for designing and enhancing precision machines to perform under demanding conditions.

Purpose of the Study:

• To analyze the performance of a high-precision machine tool using a virtual model and finite element modeling (FEM).
• To investigate the static and dynamic characteristics, including structural deformation, stiffness, and natural frequencies.
• To optimize the machine tool structure for reduced weight, deformation, and increased natural frequency.

Main Methods:

• Created a virtual model of the machine tool using CAD.
• Performed static and modal analyses using ANSYS Workbench.
• Conducted experimental static rigidity analysis for validation.
• Utilized transient analysis for response under load and topology optimization.

Main Results:

• Identified natural frequencies at 22.5, 28.9, 40.6, and 47.4 Hz, indicating potential weak links.
• Determined spindle deformation of 67.26 μm under static load.
• Validated FEM results against experimental data with an error margin below 1.56%.
• Transient analysis showed a 0.5 s response for the tool nose under a 5000 N load.

Conclusions:

• The finite element analysis model accurately represents the static and dynamic characteristics of the machine tool.
• Topology optimization can achieve a lightweight structure with reduced deformation and enhanced natural frequency.
• The developed method improves structural optimization, manufacturability, and offers cost-effective design options.