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Design optimization approach of a large-scale moving framework for a large 5-axis machining center

Design optimization approach of a large-scale moving framework for a large 5-axis machining center
Design optimization approach of a large-scale moving framework for a large 5-axis machining center

The traditional machine tool design method with metal materials makes large-scale moving structures very heavy, which seriously impacts dynamic performance and results in significant energy consumption. Using sandwich structures of composite materials to replace metal materials is an important strategy for lightweight large-scale moving structures. However, this kind of substitution is generally believed to be difficult because foam-filled sandwich structures usually show nonlinear characteristics and must balance the moving mass, material costs, and structural stiffness. In the present study, we proposed a design optimization approach for a large-scale moving framework in a large 5-axis machining center (L5AMC) considering large dimensions in the x, y, and z work space and high machining speed with the aim of minimizing the displacements of the milling head. An improved approach, named the 3-step design optimization, was executed to obtain the optimum framework structures to solve the contradiction between the moving mass, material costs, and structural stiffness. This approach was based on multi-objective optimization and finite element analysis. The structural stiffness of the framework after optimization increased by 89% compared with before optimization although the mass increased by 6% and the material costs increased by 9%. A finite element simulation under four given operational loads showed that the displacements of the milling head were all less than the design requirement of 0.25 mm. The results indicated that the proposed 3-step design optimization approach for the optimal design of a large-scale moving framework was feasible and successful. A 40 m × 6 m × 4 m L5AMC prototype was manufactured, and the actual verification results indicated that the large-scale moving framework fully met the design requirements of the L5AMC and reduced energy consumption.

3-step design optimization, Finite element analysis, Large-scale moving structure, Multi-objective optimization, Sandwich structure
2076-3417
Zhong, Gaoyan
4122f394-9978-4435-874b-5e8356d19a31
Liu, Ping
41ff5c8a-4b8a-4010-b1a9-eb6d03716591
Mei, Xinliang
c722b96e-beab-484f-a41b-a08443b32a6d
Wang, Yanqing
67d2408f-649d-425b-bfb4-96f576cdf369
Xu, Fang
17d83cd9-99b6-4e0c-859e-01b03ec5ff1f
Yang, Shoufeng
e0018adf-8123-4a54-b8dd-306c10ca48f1
Zhong, Gaoyan
4122f394-9978-4435-874b-5e8356d19a31
Liu, Ping
41ff5c8a-4b8a-4010-b1a9-eb6d03716591
Mei, Xinliang
c722b96e-beab-484f-a41b-a08443b32a6d
Wang, Yanqing
67d2408f-649d-425b-bfb4-96f576cdf369
Xu, Fang
17d83cd9-99b6-4e0c-859e-01b03ec5ff1f
Yang, Shoufeng
e0018adf-8123-4a54-b8dd-306c10ca48f1

Zhong, Gaoyan, Liu, Ping, Mei, Xinliang, Wang, Yanqing, Xu, Fang and Yang, Shoufeng (2018) Design optimization approach of a large-scale moving framework for a large 5-axis machining center. Applied Sciences (Switzerland), 8 (9), [1598]. (doi:10.3390/app8091598).

Record type: Article

Abstract

The traditional machine tool design method with metal materials makes large-scale moving structures very heavy, which seriously impacts dynamic performance and results in significant energy consumption. Using sandwich structures of composite materials to replace metal materials is an important strategy for lightweight large-scale moving structures. However, this kind of substitution is generally believed to be difficult because foam-filled sandwich structures usually show nonlinear characteristics and must balance the moving mass, material costs, and structural stiffness. In the present study, we proposed a design optimization approach for a large-scale moving framework in a large 5-axis machining center (L5AMC) considering large dimensions in the x, y, and z work space and high machining speed with the aim of minimizing the displacements of the milling head. An improved approach, named the 3-step design optimization, was executed to obtain the optimum framework structures to solve the contradiction between the moving mass, material costs, and structural stiffness. This approach was based on multi-objective optimization and finite element analysis. The structural stiffness of the framework after optimization increased by 89% compared with before optimization although the mass increased by 6% and the material costs increased by 9%. A finite element simulation under four given operational loads showed that the displacements of the milling head were all less than the design requirement of 0.25 mm. The results indicated that the proposed 3-step design optimization approach for the optimal design of a large-scale moving framework was feasible and successful. A 40 m × 6 m × 4 m L5AMC prototype was manufactured, and the actual verification results indicated that the large-scale moving framework fully met the design requirements of the L5AMC and reduced energy consumption.

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applsci-08-01598-v2 - Version of Record
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More information

Accepted/In Press date: 5 September 2018
e-pub ahead of print date: 10 September 2018
Published date: 10 September 2018
Keywords: 3-step design optimization, Finite element analysis, Large-scale moving structure, Multi-objective optimization, Sandwich structure

Identifiers

Local EPrints ID: 423497
URI: http://eprints.soton.ac.uk/id/eprint/423497
ISSN: 2076-3417
PURE UUID: d0a967fc-3671-4760-b6a8-26bff0750481
ORCID for Shoufeng Yang: ORCID iD orcid.org/0000-0002-3888-3211

Catalogue record

Date deposited: 25 Sep 2018 16:30
Last modified: 27 Jan 2020 13:44

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Contributors

Author: Gaoyan Zhong
Author: Ping Liu
Author: Xinliang Mei
Author: Yanqing Wang
Author: Fang Xu
Author: Shoufeng Yang ORCID iD

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