Modelling and Analysis of CNC Milling Machine Bed with Composite Material
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This document presents a study on the modeling and analysis of a CNC milling machine bed made of high modulus carbon fiber reinforced polymer (HM CFRP) to improve its structural performance compared to traditional materials like cast iron and steel. The research highlights the advantages of composite materials, including increased stiffness, reduced weight, and enhanced damping characteristics, essential for high-speed machining operations. Through various analyses, the study concludes that HM CFRP significantly reduces deformation and strain, making it an ideal choice for CNC machine beds, enhancing precision and accuracy in manufactured components.
![IJSRD - International Journal for Scientific Research & Development| Vol. 2, Issue 09, 2014 | ISSN (online): 2321-0613
All rights reserved by www.ijsrd.com 5
Modelling and Analysis of CNC Milling Machine Bed with Composite
Material
Venkata Ajay Kumar. G1
V. Venkatesh2
1,2
Assistant Professor
1
Department of Mechanical Engineering
1,2
Annamacharya Institute of Technology & Sciences, Rajampeta
Abstract— Structural materials used in a machine tool have
a decisive role in determining the productivity and accuracy
of the part manufactured in it. The conventional structural
materials used in precision machine tools such as cast iron
and steel at high operating speeds develop positional errors
due to the vibrations transferred into the structure. Faster
cutting speeds can be acquired only by structure which has
high stiffness and good damping characteristics. Clearly the
life of a machine is inversely proportional to the levels of
vibration that the machine is subjected. The further process
is carried out to undergo the deformation, natural frequency
and displacement using Static analysis, Modal analysis and
Harmonic analysis respectively. Since the bed in machine
tool plays a critical role in ensuring the precision and
accuracy in components. It is one of the most important tool
structures which tend to absorb the vibrations resulting from
the cutting operation. To analyze the bed for possible
material changes that could increase stiffness, reduce
weight, improve damping characteristics and isolate natural
frequency from the operating range. This was the main
motivation behind the idea to go in for a composite model
involving High Modulus Carbon Fiber Reinforced Polymer
Composite Material (HM CFRP). Though carbon has good
strength and stiffness properties but it lacks in damping
requirements. On the other hand polymer, though it lacks in
strength but it has good damping characteristics and it is
used to hold the carbon fibers. This makes it ideal to
combine these materials in a proper manner. In this work, a
machine bed is selected for the analysis static loads. Then
investigation is carried out to reduce the weight of the
machine bed without deteriorating its structural rigidity. The
3D CAD model of the bed has been created by using
commercial 3D modelling software and analyses were
carried out using ANSYS.
Key words: Composite material, hybrid structures, machine
bed.
I. INTRODUCTION
The transfer of high speed as well as the high cutting speed
of machine tools is very essential important for the
improvement of productivity. It ensures not only faster
cutting rates but also lesser cutting force. Faster cutting
speeds can be acquired only by structure which has high
stiffness and good damping characteristics. The deformation
of machine tool structure under cutting forces and loads
which leads to the poor quality of products with less
accuracy, both dimensional as well as geometrical of the
product. So, the level of deformation and vibration that
determines the components with high precision. Clearly the
life of a machine is inversely proportional to the levels of
vibration that the machine is subjected. The further process
is carried out to under goes the deformation, natural
frequency and displacement using Static analysis, Modal
analysis and Harmonic analysis respectively. To analyse the
bed for possible material changes that could increase
stiffness, reduce weight, improve damping characteristics
and isolate natural frequency from the operating range.
At present the Machine Beds are made of grey Cast
Iron material, which cause a number of problems in
Machine tools. Cast Iron cannot with stand the sudden loads
during operation whenever the load reaches Ultimate loads
it Simply fails without any prior indication. Casting is only
the Manufacturing process used to produce the beds. This
Process leads to various Casting Defects in the component.
In order to have high strength and high stiffness the weight
of the machine bed should be high.
II. NEED OF COMPOSITE MATERIALS
A. Selvakumar [1] work states that same stiffness, the epoxy
granite structure offers a considerable weight reduction,
along with high damping characteristics. The epoxy granite
structure offers a sharp reduction in mass along with high
damping ratio. S. Syath Abuthakeer [2] proposed how to
improve static and dynamic characteristics on a CNC
machine. Simulation results show that the static and
dynamic performances of vertical ribs with hollow bed have
been improved. Structural vertical ribs with hollow offers a
method to improve the conventional design of machine
structure. Based on structural modifications, ribs parameters
and distributions can be further optimized. A. Merlo [3]
analyzed the combination of hybrid materials (steel, CFRP,
Al honeycomb) and an intensive use of gluing technology
allows to increase damping and, at the same time, to get a
consistent mass reduction (up to 40%) without reducing the
overall stiffness. Sivarao [4] Investigation of Tangential
Force, Horsepower and Material Removal Rate Associating
HAAS CNC Milling, Al6061-T6511 Work Material &
TiAlN Coated End Mill Tool. This journal gives about
calculation of cutting forces in milling machine process.
Thirumaleswara Bhat Anil Antony Sequeira [5] Modified
Approach for Cutting Force Measurement in Face Milling
Process. This journal gives about calculation of cutting
forces in milling machine process.](https://image.slidesharecdn.com/ijsrdv2i9013-150923122636-lva1-app6892/85/Modelling-and-Analysis-of-CNC-Milling-Machine-Bed-with-Composite-Material-1-320.jpg)
![Modelling and Analysis of CNC Milling Machine Bed with Composite Material
(IJSRD/Vol. 2/Issue 09/2014/002)
All rights reserved by www.ijsrd.com 8
3
1360.
9
26.283 1580 25.745
2253.
9
29.605
4
1956.
8
15.414
2269.
7
14.626
3240.
8
17.274
5
2183.
3
22.879
2541.
8
22.315
3617.
7
25.759
6 2537 21.179
2974.
1
20.929
4209.
1
23.9
Table 7.2 Comparison of Results from Modal Analysis
VIII. CONCLUSIONS
Based on the configuration principles, the existing bed
material was replaced by HM CFRP material shows
improve in the static characteristics. Simulations results
show that the static characteristics of the machine bed have
been improved. Generally Composite materials also offer
high specific strength and high specific modulus with less
weight in machine tool industries. This composite materials
offers high accuracy and precession of the component
manufactured in such machine tools made of composite
materials. By considering all the results, the induced
deformation and strain in HM CFRP machine bed is less
than conventional cast iron machine beds because specific
strength and specific rigidity of HMCFRP machine bed is
more than cast iron. The work suggests that HM CFRP
material is best suited for CNC milling machine bed.
REFERENCES
[1] A.Selvakumar, P.V. Mohanram, “Analysis of
alternative composite material for high speed precision
machine tool structures” International journal of
Engineering, 2, pp.95-98, 2012.
[2] S. Syath Abuthakeer, P.V. Mohanram, G. Mohan
kumar, “Structural redesigning of a CNC lathe bed to
improve its static and dynamic characteristics”,
International journal of Engineering, 2, pp.389-394,
2011.
[3] Merlo, D. Ricciardi, A. Cremona, F. Meo, F. Aggogeri,
“Advanced composite materials in precision machine
tools sector – Applications and perspectives”, 2013.
[4] Sivarao, Fairuz Dimin, T.J.S.Anand, A.Kamely, Kamil
“Investigation of Tangential Force, Horsepower and
Material Removal Rate Associating HAAS CNC
Milling”, Al6061-T6511 Work Material & TiAlN
Coated End Mill Tool.
[5] Anil Antony Sequeira, “Modified Approach for Cutting
Force Measurement for Face in Milling”, Innovative
Systems Design and Engineering, 4, 2012.](https://image.slidesharecdn.com/ijsrdv2i9013-150923122636-lva1-app6892/85/Modelling-and-Analysis-of-CNC-Milling-Machine-Bed-with-Composite-Material-4-320.jpg)
Modelling and Analysis of CNC Milling Machine Bed with Composite Material
- 1. IJSRD - International Journal for Scientific Research & Development| Vol. 2, Issue 09, 2014 | ISSN (online): 2321-0613 All rights reserved by www.ijsrd.com 5 Modelling and Analysis of CNC Milling Machine Bed with Composite Material Venkata Ajay Kumar. G1 V. Venkatesh2 1,2 Assistant Professor 1 Department of Mechanical Engineering 1,2 Annamacharya Institute of Technology & Sciences, Rajampeta Abstract— Structural materials used in a machine tool have a decisive role in determining the productivity and accuracy of the part manufactured in it. The conventional structural materials used in precision machine tools such as cast iron and steel at high operating speeds develop positional errors due to the vibrations transferred into the structure. Faster cutting speeds can be acquired only by structure which has high stiffness and good damping characteristics. Clearly the life of a machine is inversely proportional to the levels of vibration that the machine is subjected. The further process is carried out to undergo the deformation, natural frequency and displacement using Static analysis, Modal analysis and Harmonic analysis respectively. Since the bed in machine tool plays a critical role in ensuring the precision and accuracy in components. It is one of the most important tool structures which tend to absorb the vibrations resulting from the cutting operation. To analyze the bed for possible material changes that could increase stiffness, reduce weight, improve damping characteristics and isolate natural frequency from the operating range. This was the main motivation behind the idea to go in for a composite model involving High Modulus Carbon Fiber Reinforced Polymer Composite Material (HM CFRP). Though carbon has good strength and stiffness properties but it lacks in damping requirements. On the other hand polymer, though it lacks in strength but it has good damping characteristics and it is used to hold the carbon fibers. This makes it ideal to combine these materials in a proper manner. In this work, a machine bed is selected for the analysis static loads. Then investigation is carried out to reduce the weight of the machine bed without deteriorating its structural rigidity. The 3D CAD model of the bed has been created by using commercial 3D modelling software and analyses were carried out using ANSYS. Key words: Composite material, hybrid structures, machine bed. I. INTRODUCTION The transfer of high speed as well as the high cutting speed of machine tools is very essential important for the improvement of productivity. It ensures not only faster cutting rates but also lesser cutting force. Faster cutting speeds can be acquired only by structure which has high stiffness and good damping characteristics. The deformation of machine tool structure under cutting forces and loads which leads to the poor quality of products with less accuracy, both dimensional as well as geometrical of the product. So, the level of deformation and vibration that determines the components with high precision. Clearly the life of a machine is inversely proportional to the levels of vibration that the machine is subjected. The further process is carried out to under goes the deformation, natural frequency and displacement using Static analysis, Modal analysis and Harmonic analysis respectively. To analyse the bed for possible material changes that could increase stiffness, reduce weight, improve damping characteristics and isolate natural frequency from the operating range. At present the Machine Beds are made of grey Cast Iron material, which cause a number of problems in Machine tools. Cast Iron cannot with stand the sudden loads during operation whenever the load reaches Ultimate loads it Simply fails without any prior indication. Casting is only the Manufacturing process used to produce the beds. This Process leads to various Casting Defects in the component. In order to have high strength and high stiffness the weight of the machine bed should be high. II. NEED OF COMPOSITE MATERIALS A. Selvakumar [1] work states that same stiffness, the epoxy granite structure offers a considerable weight reduction, along with high damping characteristics. The epoxy granite structure offers a sharp reduction in mass along with high damping ratio. S. Syath Abuthakeer [2] proposed how to improve static and dynamic characteristics on a CNC machine. Simulation results show that the static and dynamic performances of vertical ribs with hollow bed have been improved. Structural vertical ribs with hollow offers a method to improve the conventional design of machine structure. Based on structural modifications, ribs parameters and distributions can be further optimized. A. Merlo [3] analyzed the combination of hybrid materials (steel, CFRP, Al honeycomb) and an intensive use of gluing technology allows to increase damping and, at the same time, to get a consistent mass reduction (up to 40%) without reducing the overall stiffness. Sivarao [4] Investigation of Tangential Force, Horsepower and Material Removal Rate Associating HAAS CNC Milling, Al6061-T6511 Work Material & TiAlN Coated End Mill Tool. This journal gives about calculation of cutting forces in milling machine process. Thirumaleswara Bhat Anil Antony Sequeira [5] Modified Approach for Cutting Force Measurement in Face Milling Process. This journal gives about calculation of cutting forces in milling machine process.
- 2. Modelling and Analysis of CNC Milling Machine Bed with Composite Material (IJSRD/Vol. 2/Issue 09/2014/002) All rights reserved by www.ijsrd.com 6 III. METHODOLOGY Fig. 1 Flow chart for the process IV. MACHINE BED Machine Bed supports the all elements like column, work table and servo motors. Whatever the cutting force induced in the machining process is simply transformed to machine bed, and machine beds absorb the vibrations induced in the machining process. Machine bed contains hole for accommodating lead screw which drives the work table. So that work piece can be moved as per the user programming code. It also supports the column on the rear end of it with the help of lead screws. Machine beds withstand the various forces generated during the cutting. In order to produce the accurate products a machine bed should have high structural stiffness with good damping coefficient, these are the two major design factors considered while the design of machine bed. Whenever machining operation starts machine bed experiences cutting forces. These cutting forces can be divided into three types; they are tangential cutting force, feed force and radial force. The loads applied on the machine bed are calculated as. Total weight of Machine = 170 Kg. Load acting on rear end of Machine Bed = 73Kg. Weight of the Work Table = 18Kg. Total forces acting on guide ways = cutting force + weight of work table and work piece = 95 + (18*9.81) = 272N Force due to other accessories = 73 * 9.81= 717N All the above calculated loads are applied on the machine bed during the analysis of the machine bed. V. MATERIAL DISCUSSION Composite materials are engineered materials made from two or more constituent material with significantly different physical or chemical properties and which remain separate and distinct on a macroscopic level with in the finished structure. There are several reasons for the re-emergence of interest in metal- matrix composites, the most important one being their engineering properties. MMCs are of light weight, and exhibit good stiffness and low specific weight. It is generally considered that these materials offer savings in weight, at the same time maintaining their properties. MMCs also have other advantages as well, like strength, fracture toughness, thermal stability, and ductility and enhanced elevated temperature performances. However, cost remains a major point of interest for commercial applications of MMCs in future. Rapid development in MMCs has been recorded in the past few years, but these have not been cost- conscious efforts. More recently, reduction in processing costs; costs of raw material and the desirability of special properties have generated a great amount of interest. Our fiber composites are made of carbon fibers and a matrix, which consists of special resin systems or thermoplastic materials. Both components come together to give the material its specific and unusual characteristics. In doing so, fiber and matrix each have different tasks. The strength and corrosion resistance, as well as the light weight of carbon fiber is only possible as a composite material. Depending on the application, quantity and finish required, the manufacturing process of carbon fiber can vary. The basic processes include molding, vacuum bagging, compression molding and filament winding. Molding produces graphite-epoxy parts by a layering process whereby sheets of carbon fiber cloth can be placed into molds to achieve a specific product shape. This creates strong and corrosion resistant pieces. VI. MODELING AND ANALYSIS OF MACHINE BED A 3D model of the CNC machine bed was created in the CATIA V5 R20 software and saved in the iges format and importing in to Ansys work bench. The analysis was carried out on three materials cast iron, stainless steel and HM CFRP. In this stage Force and displacement boundary condition were applied as follows forces, front end of the machine bed carries cutting force, weight of the work table and weight of the work piece, due to this a total load of 272 N is applied on the Guide ways of Machine bed. Rear end of the Machine bed carries vertical column, and other accessories (ie servo motors, spindles etc..), due to this a total load of 717N will be applied on two flat surfaces of rear end. Fig.2. Machine bed model in CATIA
- 3. Modelling and Analysis of CNC Milling Machine Bed with Composite Material (IJSRD/Vol. 2/Issue 09/2014/002) All rights reserved by www.ijsrd.com 7 Fig.3. Forces applied on the machine bed A. Static Analysis a) b) c) Fig.3. Total Deformation a) cast iron b) stainless steel c) HM CFRP B. Normal Stress and Normal Strain Fig.4. Normal stress induced a) cast iron b) stainless steel c) HM CFRP ; Normal Strain induced d) cast iron e) stainless steel f) HM CFRP C. Harmonic Analysis a) b) c) Fig.5. Total Deformation due to harmonically varying loads a) cast iron b) stainless steel c) HM CFRP VII. RESULTS AND DISCUSSIONS Static analysis for comparison of the results obtained from the analysis under static load condition is given below tabular column. Cast iron Steel HM CFRP Total Deformation (mm) 3.9449×10- 5 2.652×10-5 2.0543×10- 5 Normal Stress (mpa) 0.040435 0.036949 0.040435 Normal Strain (mpa) 2.5335×10- 7 1.4113×10- 7 1.3193×10- 7 Table 1 Comparison of Static Structural Analysis Results From the above results following points to be noted Total deformation of HM CFRP composite machine bed is less than the deformation due to both Steel and Cast Iron due to its high Young’s Modulus than both Steel and Cast Iron. Since stress is independent of Material Property, hence stress induced all the machine beds is approximately same because there is no design modification. Normal Strain of HM CFRP composite machine bed is less than the both Steel and Cast Iron due to its high Young’s Modulus than both Steel and Cast Iron. Mo des Cast iron Steel HM CFRP Frequ ency (Hz) Defor mation (mm) Frequ ency (Hz) Defor mation (mm) Frequ ency (Hz) Defor mation (mm) 1 703.0 7 18.12 821.0 2 17.72 1165. 6 20.104 2 955.4 7 15.507 1120 15.322 1585. 2 17.493
- 4. Modelling and Analysis of CNC Milling Machine Bed with Composite Material (IJSRD/Vol. 2/Issue 09/2014/002) All rights reserved by www.ijsrd.com 8 3 1360. 9 26.283 1580 25.745 2253. 9 29.605 4 1956. 8 15.414 2269. 7 14.626 3240. 8 17.274 5 2183. 3 22.879 2541. 8 22.315 3617. 7 25.759 6 2537 21.179 2974. 1 20.929 4209. 1 23.9 Table 7.2 Comparison of Results from Modal Analysis VIII. CONCLUSIONS Based on the configuration principles, the existing bed material was replaced by HM CFRP material shows improve in the static characteristics. Simulations results show that the static characteristics of the machine bed have been improved. Generally Composite materials also offer high specific strength and high specific modulus with less weight in machine tool industries. This composite materials offers high accuracy and precession of the component manufactured in such machine tools made of composite materials. By considering all the results, the induced deformation and strain in HM CFRP machine bed is less than conventional cast iron machine beds because specific strength and specific rigidity of HMCFRP machine bed is more than cast iron. The work suggests that HM CFRP material is best suited for CNC milling machine bed. REFERENCES [1] A.Selvakumar, P.V. Mohanram, “Analysis of alternative composite material for high speed precision machine tool structures” International journal of Engineering, 2, pp.95-98, 2012. [2] S. Syath Abuthakeer, P.V. Mohanram, G. Mohan kumar, “Structural redesigning of a CNC lathe bed to improve its static and dynamic characteristics”, International journal of Engineering, 2, pp.389-394, 2011. [3] Merlo, D. Ricciardi, A. Cremona, F. Meo, F. Aggogeri, “Advanced composite materials in precision machine tools sector – Applications and perspectives”, 2013. [4] Sivarao, Fairuz Dimin, T.J.S.Anand, A.Kamely, Kamil “Investigation of Tangential Force, Horsepower and Material Removal Rate Associating HAAS CNC Milling”, Al6061-T6511 Work Material & TiAlN Coated End Mill Tool. [5] Anil Antony Sequeira, “Modified Approach for Cutting Force Measurement for Face in Milling”, Innovative Systems Design and Engineering, 4, 2012.