Swami et al, International Journal of Advanced Engineering Technology E-ISSN 0976-3945

Research Paper
DESIGN AND STRUCTURAL ANALYSIS OF CNC VERTICAL
MILLING MACHINE BED
B. Malleswara Swami1, K.Sunil Ratna Kumar2

Address for Correspondence

1
PG Student, 2Assistant Professor
Department of Mechanical Engineering, SIR C.R.R. College of Engineering
(Affiliated to Andhra University) Eluru-534007, West Godavari Dist, A.P
ABSTRACT
In this paper, a machine bed (Manufacturer: M/s Lokesh Machine Tools Ltd) is selected for the complete analysis for both
static and dynamic loads. Then investigation is carried out to reduce the weight of the machine bed without deteriorating its
structural rigidity and the accuracy of the machine tool by adding ribs at the suitable locations. In this work, the 3D CAD
model for the base line and the optimized design has been created by using commercial 3D modeling software CATIA. The
3D FE model has been generated using HYPERMESH. The analyses were carried out using ANSYS and Design
Optimization is done with the help of Optistruct. The results were shown with the help of graphs to analyze the effect of
weight reduction on the structural integrity of the machine bed before and after the weight reduction and conclusions were
drawn about the optimized design.
KEYWORDS: Structural integrity, Design optimization, CNC; Vertical Milling Machine
1.0 INTRODUCTION 2.0 MODELING AND SIMULATION OF
In the vertical mill the spindle axis is vertically MILLING MACHINE BED
oriented. Milling cutters are held in the spindle and The major dimensions of the machine bed are as
rotate on its axis. The spindle can generally be follows:
extended (or the table can be raised/lowered, giving Length = 1698 mm (in X-direction).
the same effect), allowing plunge cuts and drilling. Width = 1100 mm (in Y-direction).
There are two subcategories of vertical mills: the bed Height = 510 mm (in Z-direction) (up to the table level).
mill and the turret mill. Height = 940 mm (in Z-direction) (total height).
Bed width (between guide ways) = 394 mm (in Y-
• A turret mill has a stationary spindle and the direction).
table is moved both perpendicular and parallel to Total Bed width = 485 mm (in Y-direction).
the spindle axis to accomplish cutting. The most
common example of this type is the Bridgeport,
described below. Turret mills often have a quill
which allows the milling cutter to be raised and
lowered in a manner similar to a drill press. This
type of machine provides two methods of cutting
in the vertical (Z) direction: by raising or
lowering the quill, and by moving the knee.

Figure.2: 3D CAD model of milling machine bed (base

line design).
APPLYING LOADS AND BOUNDARY
CONDITIONS
Load 3924 N
Load 9810 N
Load 6907 N
Fixed constraint
Figure.1:Vertical Milling machine bed
• In the bed mill, however, the table moves only
perpendicular to the spindle's axis, while the
spindle itself moves parallel to its own axis.
Turret mills are generally considered by some to be
more versatile of the two designs. However, turret
mills are only practical as long as the machine
remains relatively small. As machine size increases,
moving the knee up and down requires considerable
Figure.3: Various loads applied on milling machine bed
effort and it also becomes difficult to reach the quill
3.0 FINITE ELEMENT ANALYSIS OF
feed handle (if equipped). Therefore, larger milling
MILLING MACHINE BED
machines are usually of the bed type. Also of note is
Material Properties:
a lighter machine, called a mill-drill. It is quite
popular with hobbyists, due to its small size and
lower price. A mill-drill is similar to a small drill
press but equipped with an X-Y table. These are
frequently of lower quality than other types of
machines.

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 Swami et al, International Journal of Advanced Engineering Technology
Figure.4: Vonmesis stress of milling machine bed of cast
iron G15
MODAL ANALYSIS
Figure.5: Mode shapes 1 for Cast iron G15
Figure.6: Vonmesis stress for cast iron G40
Figure.7: Mode Shape 1 for cast iron G40
Figure.9: Vonmesis stress for cast iron G70
Figure.10: Mode Shape 1 for cast iron G70
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E-ISSN 0976-3945
4.0 OPTISTRUCT
Altair OptiStruct is a finite element and multi-body
dynamics software for the design, analysis, and
optimization of structures and mechanical systems.
Figure.11: Element Densities of the Optistruct
This is done to check the locations/ areas where a
structure's mass can be reduced and or removed. This
is done with the help of OPTISTRUCT. In this
analysis the model is divided into two zones namely
design space and non-design space.
The design space means the area which is allowed for
changes to be made whereas the non-design space
indicates critical regions which can not be modified.
Suitable design variables are to be selected by
specifying their upper and lower bounds and
objective function is to be chosen for either
maximization or minimization
5.0 MODELLING & SIMULATION FOR
OPTIMIZED MILLING MACHINE BED
The size optimization of is done to check the
locations/ areas where a structure's mass can be
reduced and or removed. This is done with the help
of OPTISTRUCT.
Figure.12: 3D cad model of Milling machine
bed(optimized design)
In fig 13 was the optimized cad we have to remove
some masses from the original body. Then optimized
model we have to import the Hyper mesh software
then meshing was start to as follows
Figure.13: Von messis Stress of Optimized Milling
Machine Bed cast iron G15
 Swami et al, International Journal of Advanced Engineering Technology E-ISSN 0976-3945

Optristruct are presented. Also the effects of mass

reduction on the static and dynamic performance of
the machine bed are discussed detail.
6.1 Results of Static structural analysis
The results for Linear static, 1g static and modal
analysis for comparison original cad and optimized
cad baseline model of the machine bed are presented
in this section.
Table .1 Displacements of milling machine bed

Figure.14: Vonmesis stress of optimized Milling

machine bed of cast iron G40

Figure.15: Vonmesis stress of milling machine bed of Figure.19: comparison between displacement vectors of
cast iron G70 initial model and optimize model of milling machine
bed
It is observed that cast iron is having more ductility
and hence having more displacement. As Cast Iron is
having moderate ductility, it is observed to have
moderate displacement. Next comesG15 with least
displacement and there is not much effect of fillet
radius on displacement.
Table.2 Vonmesis Strain Of Milling Machine Bed:

Figure.16: Vonmesis stress of optimize milling Table.3 Maximum Principle stress of milling machine
machine bed of cast iron G70 Bed

Table.4 Minimum Principle Stress of milling machine

Bed

Table.5 Vonmessis stress of milling machine bed:

Figure.17: Modal shape 1 of Cast Iron G15
Optimization Of Milling Machine Bed

Figure.18: Modal shape1 for G40 optimization Of

Milling machine Bed
6.0 RESULTS & DISCUSSION Figure.20: comparison between Vonmesis Stress of
The results of static structural analysis and modal initial model and optimize model of milling machine
using ANSYS and the optimization study using bed

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 Swami et al, International Journal of Advanced Engineering Technology
Table .6 Modal analysis results for cast iron G15
Table.7 Modal Analysis Results Forg40
Table.8 Modal Analysis Results For G70
Table.9 Comparison of weight of milling machine bed
Figure.21: Comparison Weights of initial model and
optimize model of milling machine bed
7.0 CONCLUSION
The following points are concluded on a milling
machine bed
• From the above results, the weight
optimization of milling machine bed structure
has been decrease by 16.1 Kg from 1056.31Kg
to 1040.2 Kg (approximately 1.5%), hence the
manufacturing cost also has been reduced.
• From the above results, the G15 was selected
as the best material due to low stresses and
high natural frequencies, when it is compared
with other materials,
• The von-mises stress for G15 was increased
from 26.1305 to 33.2082 N/mm2 in structural
analysis. (Approximately 21.31%).
• The natural frequency is also incresed.200 Hz
to 215 Hz (approximately 6.9%).
• The Effect of Vonmesis stress for G15 was
increased and it is in permissible safe limit.
• Structural 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.
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