Structure Design Improvement and Stiffness Reinforcement of a Machine Tool through Topology Optimization Based on Machining Characteristics
Machining characteristics were applied to topology optimization for machine tool structure design improvement in this study, and the goals of lightweight and high rigidity of the structure were achieved. Firstly, an ultrasonic-assisted grinding experiment was carried out on zirconia to investigate t...
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-12-01
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| Series: | Applied Sciences |
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| Online Access: | https://www.mdpi.com/2076-3417/14/1/61 |
| _version_ | 1797359162283261952 |
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| author | Shen-Yung Lin Chun-Ho Chang |
| author_facet | Shen-Yung Lin Chun-Ho Chang |
| author_sort | Shen-Yung Lin |
| collection | DOAJ |
| description | Machining characteristics were applied to topology optimization for machine tool structure design improvement in this study, and the goals of lightweight and high rigidity of the structure were achieved. Firstly, an ultrasonic-assisted grinding experiment was carried out on zirconia to investigate the surface roughness, surface morphology, grinding vibration, and forces. Then, the topology optimization analysis was conducted for structure design improvement, in which the magnitude of the grinding vibration was utilized as the reference for selecting the topology subsystems and the grinding force was used as the boundary conditions of the static analysis in the topology optimization. Hence, columns, bases, and saddles were redesigned for structure stiffness improvement, and the variations in the effective stress, natural frequency, weight, and stiffness of the whole machine tool were compared accordingly. The results showed that the deduced topological shape (model) can make the natural frequency and stiffness of the whole machine tool tend to be stable and convergent with a weight retention rate more than 75% as the design constraint. The subsystem structures with larger effective stress distributions were designated for stiffness improvement in the design. At the same time, the topological shape (model) was also employed in the design for weight reduction, focusing on minimizing redundant materials within the structure. In contrast to the consistency of the modal shapes before and after topological analysis, the sequential number of the modal mode of the machine tool model after topological analysis was advanced by two modes relative to those of the original situation, which means the original machine tool may be out of its inherently resonant frequency range. Also, the natural frequencies corresponding to each mode had an increasing tendency, and the maximum increase was 110.28%. Furthermore, the stiffness of the machine tool also increased significantly, with a maximum of 355.97%, leading to minor changes of the machine tool’s weight. These results confirm that the topology optimization based on machining characteristics proposed in this study for structure redesign improvement and stiffness enhancement is effective and feasible. |
| first_indexed | 2024-03-08T15:12:40Z |
| format | Article |
| id | doaj.art-b9206b280d454317a80c0630b9ac5392 |
| institution | Directory Open Access Journal |
| issn | 2076-3417 |
| language | English |
| last_indexed | 2024-03-08T15:12:40Z |
| publishDate | 2023-12-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Sciences |
| spelling | doaj.art-b9206b280d454317a80c0630b9ac53922024-01-10T14:50:46ZengMDPI AGApplied Sciences2076-34172023-12-011416110.3390/app14010061Structure Design Improvement and Stiffness Reinforcement of a Machine Tool through Topology Optimization Based on Machining CharacteristicsShen-Yung Lin0Chun-Ho Chang1Department of Mechanical and Computer-Aided Engineering, National Formosa University, 64, Wunhua Rd., Huwei Township 632, Yunlin, TaiwanDepartment of Mechanical and Computer-Aided Engineering, National Formosa University, 64, Wunhua Rd., Huwei Township 632, Yunlin, TaiwanMachining characteristics were applied to topology optimization for machine tool structure design improvement in this study, and the goals of lightweight and high rigidity of the structure were achieved. Firstly, an ultrasonic-assisted grinding experiment was carried out on zirconia to investigate the surface roughness, surface morphology, grinding vibration, and forces. Then, the topology optimization analysis was conducted for structure design improvement, in which the magnitude of the grinding vibration was utilized as the reference for selecting the topology subsystems and the grinding force was used as the boundary conditions of the static analysis in the topology optimization. Hence, columns, bases, and saddles were redesigned for structure stiffness improvement, and the variations in the effective stress, natural frequency, weight, and stiffness of the whole machine tool were compared accordingly. The results showed that the deduced topological shape (model) can make the natural frequency and stiffness of the whole machine tool tend to be stable and convergent with a weight retention rate more than 75% as the design constraint. The subsystem structures with larger effective stress distributions were designated for stiffness improvement in the design. At the same time, the topological shape (model) was also employed in the design for weight reduction, focusing on minimizing redundant materials within the structure. In contrast to the consistency of the modal shapes before and after topological analysis, the sequential number of the modal mode of the machine tool model after topological analysis was advanced by two modes relative to those of the original situation, which means the original machine tool may be out of its inherently resonant frequency range. Also, the natural frequencies corresponding to each mode had an increasing tendency, and the maximum increase was 110.28%. Furthermore, the stiffness of the machine tool also increased significantly, with a maximum of 355.97%, leading to minor changes of the machine tool’s weight. These results confirm that the topology optimization based on machining characteristics proposed in this study for structure redesign improvement and stiffness enhancement is effective and feasible.https://www.mdpi.com/2076-3417/14/1/61machining characteristicsstiffness reinforcementdesign improvementtopology optimization |
| spellingShingle | Shen-Yung Lin Chun-Ho Chang Structure Design Improvement and Stiffness Reinforcement of a Machine Tool through Topology Optimization Based on Machining Characteristics Applied Sciences machining characteristics stiffness reinforcement design improvement topology optimization |
| title | Structure Design Improvement and Stiffness Reinforcement of a Machine Tool through Topology Optimization Based on Machining Characteristics |
| title_full | Structure Design Improvement and Stiffness Reinforcement of a Machine Tool through Topology Optimization Based on Machining Characteristics |
| title_fullStr | Structure Design Improvement and Stiffness Reinforcement of a Machine Tool through Topology Optimization Based on Machining Characteristics |
| title_full_unstemmed | Structure Design Improvement and Stiffness Reinforcement of a Machine Tool through Topology Optimization Based on Machining Characteristics |
| title_short | Structure Design Improvement and Stiffness Reinforcement of a Machine Tool through Topology Optimization Based on Machining Characteristics |
| title_sort | structure design improvement and stiffness reinforcement of a machine tool through topology optimization based on machining characteristics |
| topic | machining characteristics stiffness reinforcement design improvement topology optimization |
| url | https://www.mdpi.com/2076-3417/14/1/61 |
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