The 6th edition of the

Interdisciplinarity in Engineering International Conference

“Petru Maior” University of Tîrgu Mureş, Romania, 2012

METHOD FOR IMPROOVING DINAMIC PROPERTIES OF

LARGE MOVING CNC MACHINE TOOL COMPONENTS
Mihai SIMON#1, Lucian GRAMA#2, Macedon GANEA*3
#
Industrial Engineering and Management Department, Petru Maior University
Nicolae Iorga Street, No. 1, Targu Mures, Romania
1
mihai_simon@yahoo.com
2
lgrama46@yahoo.com
*
Engineering and Management Department, University of Oradea
Universitatii Street, No. 1, Oradea, Romania
3
macedonganea@yahoo.com

ABSTRACT
This paper is part of a study for obtaining an experimental prototype of a large moving
machine tool structural part, by reducing its weight and increasing rigidity properties.
Weight reduction is necessary for better dynamic performance and energy efficiency .The
problem is that by reducing mass, rigidity and vibrations dampening are affected. The
developed method tries to eliminate this problem by applying alternative technologies
such as: using alternative materials, applying ribs and cut outs, obtaining a box type
shape, filling the interior space with metallic aluminum foam.

Keywords: Machine tool rigidity, mass reduction, FEM simulation, aluminum foam.

1. Introduction welded steel plates in different configurations. This

In the context of a fast growing industry, is method is used and with good improving results [11].
important on global scale, to reduce the electrical
consumption of machine tools by keeping the
machining performance [1]. This can be done with
expensive hi performance servo motors such as linear
motors, or by redesigning the large structural moving
parts. It is demonstrated that on average CNC milling
machine tool, 60% [2] of the torque of the servomotor
is used on moments of rotary and linear inertia for
acceleration and decelerations of moving parts [3].
It is critical that those mechanical parts must be as
light as possible. The problem is that rigidity and
vibrations dampening are reduced considerably by
doing so [4]. Applying new designs, new
metallurgical alternative technologies, [5] rigidity and a. b.
vibrations amortization can be improved and mass Fig.1 - Spindle motor carriers on: a. Vertical
reduced below a classically obtained part [6]. machining center; b. horizontal machining center
A large, heavy, moving component is for example
the spindle motor carrier [7]. A classical CNC
machine tool center spindle motor carrier is the
component that moves usually along Z or Y axis. It
carries the spindle (milling) motor with tool clamping
mechanism and tool assembly (Fig 1.). Usually this
component is made from cast iron [8] because it’s
properties such as: good machining, mold poring,
vibration dampening and reduced cost [9]. Problem is
its mass and environmental processing issues [10].
Some manufactures construct structures by using Fig.2 - Examples of Al foam filed structures

22
 A technique in its early stages, is filing hallow
structures with foam like materials [12] (Fig. 2.). The
most used material is metallic Al foam (Fig.3.).
Fig. 3 - Al foam mechanical characteristics [13]
2. Method used
The paper presents an alternative design of a large
mass, moving CNC milling machine tool component.
This component is an experimentally obtained spindle
motor carrier of a CNC milling machine tool center
(Fig.4.).
Fig.4 - Designed CNC milling machine tool center,
with the experimental spindle motor carrier part
The newly designed structure (Fig.5.) is improved
by applying several technics:
- Laser cut welded steel plates for constructing the
structural frame.
- Internal shape modification by applying ribs and
cut outs for stiffening and reducing weight.
- Obtaining a box type shape for increased
rigidity.
- Filling the interior space with metallic aluminum
23
foam for rigidity and vibration dampening.
This technics was assisted by FEM analysis, using
Autodesk Ansys module. The step by step results
from FEM simulation were used for improving the
design in weak points, or reducing weight were
unnecessary surplus of material.
Fig. 5 - New experimental designed structure of
the CNC milling machine spindle motor carrier.
3. Experimental results.
- 1st step was the design of an existent classic,
unmodified structure, from a performance
commercial, 2008 milling machine center.
This was made using actual measurement on a
real machine tool and remodeling the part in
Autodesk Inventor.
- The design and simulation of a new modified
part with kept functionality and size.
The design of the new part was according the
unmodified existing part, with added improved
features: other material (OL 44 instead of cast iron),
thinner walls, ribs for rigidity, cut outs for reduced
weight, plates for boxing the structure and filed
interior spaces with expanded aluminum metallic
foam.
- FEM analysis and remodeling for improved
performance in Autodesk Ansys.
Were the structure had weak points, high
amplitude deformations or points of increased
chattering frequencies, added material or
supplementary ribs were designed.
- Comparison analysis with the existing classic
unmodified structure [Table 1].
Correct materials were selected according to
production datasheets.
The metallic foam structural model and
characteristics was used from studies of MUSP Italy
and other specialty bibliography.
The controllable variables chosen for the
experimentation were stress, deformations and
several critical chattering fervencies.
The ranges of frequencies selected are found in hi
performance HSC milling machining, and covers the
whole range of CNC milling center operations.
 Table 1: Comparison analysis between the existing classic structure and the newly designed structure
Unmodified structure New designed structure
Simulation Result Simulation Result
Mass 226.3 kg 101.9 kg
Material Steel Modified structure with aluminum foam
Force 5000 N 5000 N

Stress
equivalent 13,813 3,275 Mpa
Mpa

Maximum
principal 7,28 3,78 Mpa
stress Mpa

Maximum 0,0154 0,018 mm

deformation mm

Other
deformation 0,159 0,012 mm
mm

Frequency
Mode 1 in 0,044 0.0195
Range mm mm

Frequency
Mode 2 in 0,229 0.179 mm
Range mm

Frequency
Mode 3 in 0,09 0.071
Range mm mm

Frequency
Mode 4 in 0,075 0.05 mm
Range mm

24
 4. Conclusions
Heavy moving machine parts means reduced
dynamic performance of the CNC machine tools.
This, in the context of increasing industrial demands
for beater surfaces, is an impediment by elongating
the time to machine the piece.
a.
b.
c.
d.
Fig.6 - Obtained improved spindle carrier: Laser
cut steel parts; b. ribs for rigidity; c. thermal
treatments and machining; d. finished structure.
25
The problem is that reduced mass means higher
vibrations and deformations. This paper studied a
method to reduce the mass by 50% and reduce the
stress equivalent from 13,813 Mpa to 3,275 Mpa.
Also deformations ware kept in acceptance limits,
and beater comportment at different chattering
frequency’s was achieved.
The method can be applied in other fields of
performance engineering such as automotive, bridge
constructions, ladders or other applications with good
rigidity properties and low mas.
The results were used in the end for producing
a high dynamic performance 3 axis CNC milling
machine, completed with the experimentally
improved spindle carrier (Fig. 6.).
Acknowledgment
This work was partially supported by the strategic
grant POSDRU/88/1.5/S/53501, Project ID53501
(2009), co-financed by the European Social Fund-
Investing in People, within the Sectorial Operational
Programme Human Resources Development 2007-
2013
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