International Journal of Trend in Scientific Research and Development (IJTSRD)

Volume 3 Issue 6, October 2019 Available Online: www.ijtsrd.com e-ISSN: 2456 – 6470

Design and Structural Analysis of

3 Axis CNC Milling Machine Table
Nyein Chan, Than Zaw Oo, Aung Myo San Hlaing
Department of Mechanical Engineering, Technological University, Taunggyi, Myanmar

ABSTRACT How to cite this paper: Nyein Chan |

In the field of Engineering, the solution of many complex problems is great Than Zaw Oo | Aung Myo San Hlaing
limitless and usually impossible by analytical methods. For high exactness and "Design and Structural Analysis of 3 Axis
repeatability, machine tools are used in industrial operation. Normally, several CNC Milling Machine
components such as base, knee, saddle, machine table, column and headstock, Table" Published in
column are the main parts of the machine tools to get reliable performance. International
The work piece is held and supported on the machine table. A machine table Journal of Trend in
should be enough rigid and must have good mechanical properties, to obtain a Scientific Research
good finished and accurate work piece on a three axis CNC milling machine. A and Development
finite element analysis (FEA) gives a methodical study of failure principle (ijtsrd), ISSN: 2456- IJTSRD29197
which helps for additional progress of the 3 axis machine tables. In this paper, 6470, Volume-3 |
Static Analysis is performed on machine table to find out stresses generated in Issue-6, October 2019, pp.943-948, URL:
table, deformation of the table due to its weight. The finite element analysis is https://www.ijtsrd.com/papers/ijtsrd29
done by making 3D geometry in Solidworks software and analyse by using 197.pdf
ANSYS software. The material comparison is shown in table and Grey Cast Iron
is more dependable than other materials. Copyright © 2019 by author(s) and
International Journal of Trend in
KEYWORDS: ANSYS 17, deformation, machine table, stress, strain, Solidworks Scientific Research and Development
Journal. This is an Open Access article
distributed under
the terms of the
Creative Commons
Attribution License (CC BY 4.0)
(http://creativecommons.org/licenses/b
y/4.0)
I. INTRODUCTION:
A machine table is used for the component to hold and thermal characteristics. Specially, the dynamic
support the work piece. To gain a good finished and precise characteristics show an significant role in high speed,
work piece on the three axis CNC milling machine, a table precision machine tool structures, because vibration during
should be adequate rigid and must have good mechanical the machining process results in chatter marks on the
properties. A finite element analysis (FEA) gives a machined surface and thus creates a noisy environment.
methodical study of failure principle, which helps for further
development of the three axis machine tables. While High static stiffness in contradiction of bending and torsion,
machining, three axis CNC machine table is the rectangular good dynamic characteristics as reflected by high natural
casting positioned on the base which supports the fixtures & frequency and high damping ratio. In production, good long
the work piece. The working table establish on ways on the term dimensional stability, reasonably low coefficient of
saddle. The top of the table is correctly finished and t-slots expansion, low cost and low material requirements are the
are good for clamping the work and other fixtures on it. The elementary properties of machine tool structures that
table fixed on machine structure takes vertical forces of engineers look for designing and constructing. At current the
work piece and fixtures. [1] machine beds are made of grey cast iron material, which
cause a number of problems in machine tools. Cast iron
The dynamics of the specific machining process and nature cannot with stand the sudden loads during operation
of the forces involved, the appropriate design of machine- whenever the load spreads ultimate loads it simply fails
tool structures needs a exhaustive knowledge of their forms without any previous suggestion. Casting is only the
designs and properties of the material. Freshly, examinations manufacturing process used to produce the beds. This
have been shown in the field of upgrading of structural process leads to various casting defects in the component. So
design of machine tools by improving stiffness and as to have high strength and high stiffness the weight of the
lightening weight which is especially urgent for the machine bed should be high. [3]
structural parts, such as base, knee, bed, column, worktable,
headstock, etc. The prearrangement of stiffening-ribs in II. Literature Survey
machine tool structures is a key feature for structural Parag R. Bhingardeve et. al studied Static Structural Analysis
stiffness and material consumption. So the reducing design is performed on machine table to find out stresses
of stiffening-ribs is important for machining performance performed in table, falsification of the table due to its weight.
and energy saving. It is usually accepted that the precision of The FEA is performed by making 3D geometry in CATIA
machine tools is resolute by their static, dynamic and software and analyse by using ANSYS software.

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 International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
Aleksandar Košarac et. al analysed dynamics characteristics gantry machine design is investigated via modal and static
of machine tools, especially modal parameters, have structural analysis using ANSYS software. The gantry’s
significant effect on the cutting procedure and cutting natural frequency was designed to be 202 Hz in the first
precision. Dynamic behaviour and purpose of modal vibration mode, making the machine capable of working at
parameter are shown for horizontal milling centres. For this higher speeds of up to 11530 rpm, which is appropriate not
purposes 3D CAD model of horizontal milling centre has only for rough cutting but also for finishing.
been created using CATIA software, and modal analysis
(natural frequencies and mode shapes of the machine tool The final design of the new CNC gantry machine is updated
structure) has been conducted by ANSYS Workbench and according to the obtained results. The increase in natural
APDL. Results gained by FEM modal analysis are validate by frequency during gantry design modification affects
experimental modal analysis. Modal parameters obtained complexity, increasing the weight and manufacturing cost of
experimentally and by FEM are compared, and results shows the gantry. As such, five different gantry designs are selected
satisfactory matching. for comparison. Four parameters, i.e., the first four natural
frequencies, total deformation due to mechanical forces,
Sagar Pandit Mahajan studied, the conventional structural weight and manufacturing cost are measured performance
materials used in precision machine tools such as cast iron indices. One is selected among five designs mathematically
and steel at high operating speeds develop positional errors and improved by MOGA (multi-objective genetic algorithm)
due to the vibrations transferred into the structure. Faster in ANSYS software. In the optimization process, the gantry’s
cutting speeds can be developed only by structure which has natural frequency is maximized, thus minimizing the total
high stiffness and good restraining characteristics. In this gantry weight and deformation against mechanical forces.
work, a machine bed is selected for the analysis static loads. CNC gantry machine documents for manufacturing are
Then investigation is carried out to decrease the weight of equipped, followed by modelling, casting, machining and
the machine bed without weakening its structural rigidity. assembly. To estimate and confirm the design and analysis,
The 3D CAD model of the bed has been created by using 3D an investigational modal test is performed. The tentative
modelling software and analyses were carried out using results show less than 11% error between the dynamic
ANSYS Workbench. analysis and investigational test.

Pratik Bhambhatt et. al studied by using practical data of III. Material and Method
CNC Router structure, equipped 3D CAD model for Finite
Element Analysis in Solid Works 2015. From analysis result
find value of von mises stress, strain and displacement
(deflection) for optimize structure in strength and cost.
Sriranga V Deshpande et. al presented the design and
fabrication of 3-axis milling machine. To produce pulse-
width modulation (PWM) outputs in order to run the stepper
motors that will be used in this work, Computer numerically-
controlled (CNC) machine will be comprised the use of
Arduino micro controller. A three-axis CNC milling was
formerly used exactly surfaced designed for snapping of
wood, plastic sheet and thin sheet of metal alloy by using a
rotating drill bit which its accuracy was much lesser than
using a lesser cutter technique this machine tool was
transportable and it’s controlled by the personal computer.
Design and Construction of CNC with precision Stepper
motors that contacted with the lead screw moment along
three-axis.

Vedprakash et. al reviewed the sequence of works that have

been carried out by different researchers on design, analysis,
implementation and construction of a computer numerical
controlled (CNC) mechanical systems. The main objective of
this paper was to permit the future researchers to provide a
passage into the work to improve the performance, accuracy,
efficiency and the design of CNC machine.
Seyed reza besharati researched, reciprocal and
simultaneous motion of the gantry and worktable was
projected as the gantry machine’s X-axis double motion
Fig. 1 Design Flow Chart
mechanism. The double motion mechanism was designed
based on a rack and pinion system. A new anti-backlash
IV. MATERIAL USED FOR MACHINE TOOL
system is recommended to compensate for transmission
STRUCTURE
error and backlash (simultaneously) and for use in the
double motion mechanism. Due to manufacturing The productivity and precision of the part manufactured in
boundaries of the rack and pinion systems, a new double structural materials used in a machine tool have a significant
motion mechanism based on a ball screw system is role. Material selection is a significant of quality and cost.
proposed. The dynamic and static behaviour of the final CNC The properties of the material must be acceptable to meet

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 International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
design necessities and service conditions. Most commonly A 3D model of the CNC machine bed, its supporting rib and a
used material for machine tool structure is cast iron and workpiece for real time analysis was created in SolidWorks
steel. 2017 of the dimensions:

Cast Iron Table1 Dimensions of CNC Milling Machine Table

Cast iron is mainly an alloy of iron, carbon, and silicon. From Dimension (mm)
primary times cast iron has been the most commonly used Model
Length ✕ Breadth ✕ Depth
material for machine tool structures. It may be cast into
complex and complex shapes. It is easily machined and may Work piece 500 ✕ 200 ✕ 50
be hand scraped and lapped to a high degree of accuracy. It Table 1000 ✕ 300 ✕ 141.06
has fairly good damping properties and also has reasonably
good antifriction properties helped by the graphite Saddle 381 ✕ 350 ✕ 78.14
contained in it. It can be given very good long-term
dimensional stability by giving it a special long cycle stress
Knee 304.8 ✕ 500 ✕ 396.875
relief annealing treatment. Cast iron should be preferred for
complex structures subjected to normal loading, when these VI. Design Analysis
structures are to be made large in numbers. Firstly, the design model is imported from Solid Works to
ANSYS 17. Mesh size is 5mm and node points and element
Structural steel size are 4264771 & 2798773 respectively. Material is Grey
The main condition in the selection and inspection of the Cast Iron. Display style is orthogonal quality and the 3D view
steel is the tensile strength which is used as the basis of of mesh, Total Deformation, Equivalent Stress, Equivalent
design. Strain and Maximum Principal Stress are as follow:

Generally load carrying welded structures such as frames,

beds, and column.

Steel
Steel is very widely used for machine components as it can
be manufactured and processed into a number of different
specifications each of which has a definite use. Two
properties of steel apart from strength are of special
significance in selection of proper grade of steel. First, the
maximum hardness that can be attained and second, the
harden ability which regulates the depth of hardened zone.
Fig.3 Mesh of a Milling Machine
V. Design Consideration

Fig. 4 Total Deformation of a Milling Machine

Fig.2 Isometric View of CNC Milling Table

Fig. 5 Equivalent Stress of a Milling Machine

Fig. 3 Side View of CNC Milling Table

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 International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470

Fig. 6 Elastic Strain of a Milling Machine Fig. 10 Equivalent Stress of a Milling Machine

Fig. 7 Maximum principle stress of a Milling Machine Fig. 11 Elastic Strain of a Milling Machine
Secondly, the design model is imported from SolidWorks to
ANSYS 17. Mesh size is 5mm and node points and element
size are 4264150 & 2798383 respectively. Material is
Structural Steel (ANSI 304). Display style is orthogonal
quality and the 3D view of mesh, Total Deformation,
Equivalent Stress, Equivalent Strain and Maximum Principal
Stress are as follow:

Fig. 12 Maximum principle stress of a Milling Machine

Finally, the design model is imported from SolidWorks to

ANSYS 17. Mesh size is 5mm and node points and element
size are 4260551 & 2795635 respectively. Material is
Structural Steel (ANSI 1045). Display style is orthogonal
Fig. 8 Mesh of a Milling Machine quality and the 3D view of mesh, Total Deformation,
Equivalent Stress, Equivalent Strain and Maximum Principal
Stress are as follow:

Fig. 9 Total Deformation of a Milling Machine

Fig.13 Mesh of a Milling Machine

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 International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470

Fig. 14 Total Deformation of a Milling Machine Fig. 16 Elastic Strain of a Milling Machine

Fig. 15 Equivalent Stress of a Milling Machine Fig. 17 Maximum principle stress of a Milling Machine

Table2. Comparison between Material

Result
Sr. No. Description
Gray Cast Iron ANSI 304 ANSI 1045
1. Total Deformation (mm) 1.8601e-5 1.1335e-5 2.06e-5
2. Equivalent Stress (MPa) 0.027891 0.034248 0.074173
3. Elastic Strain (mm/mm) 4.986e-7 2.2849e-7 4.9943e-7
4. Maximum Principal Stress (MPa) 0.0070949 0.020747 0.041219

VII. Conclusion
From the above tables and figures, the results are shown. As colleges, U Than Zaw Oo and U Aung Myo San Hlaing,
a result, Total Deformation of Grey Cast Iron is less than Lecturers, Department of Mechanical Engineering,
ANSI 1045 Steel but it is greater than ANSI 304 (Mild Steel).
Equivalent Stress, Elastic Strain and Maximum Principal Technological University (Taunggyi), with the help of their
Stress are 0.02789, 4.985e-7 and 0.0070949 respectively. So, guidance, constant encouragement, patient and trust, I have
for CNC Machine Table, Grey Cast Iron is more reliable than worked on this research.
other materials.
REFERENCES
ACKNOWLEDGMENT [1] Parag R. Bhingardeve, Rajani T. More, Sujit S. Malgave,
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[2] Aleksandar kosarac, milan zeljkovic, cvijetin
A special thanks is offered to Dr. Nang Woe Swam, Professor
mladenovic, aleksandar zivkovic, “Modal analysis of a
and Head of Mechanical Engineering Department,
horizontal machining center”
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preparation of this research. Kharche, “CNC Milling Bed Modelling and Analysis with
Composite Material”, International journal of
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express my sincere gratitude, respect and regards for his Vol. 1. Issue 1, 06/2016

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