2011 International Conference on Electronic & Mechanical Engineering and Information Technology

Structural Analysis and Optimization on Crossbeam of Heavy NC Gantry Moving

Boring & Milling Machine

Guihua Han 1,2,a, Bingwei Gao1,b, Junpeng Shao ' , Di wo , Xiaodong vu', Zhimin Shi'
1. Mechanical & Power Engineering College, Harbin University of Science and Technology, Harbin, China
2. Qiqihar Heavy CNC Equipment Corp. LTD. Qiqihar Heilongjiang Province, China

a.hanguihua99@yahoo.com.cn; b.gaobingwei_happy@163.com

Abstract-In order to improve the work precision, the finite
element models of cross beam of heavy NC gantry moving
boring & milling machine were established, and static/dynamic
characteristics were analyzed. The crossbeam itself stiffness
and the tip displacement converted by beam deformation
under the largest cutting force and gravity load were
calculated. According to the results of calculation and analysis,
optimal structures of the cross beam were designed, in which
structure form and size were modified. And optimal structure
was obtained by calculation cross beam itself stiffness and
crossbeam distortion of three schemes Kl, K2 and K3. The
dynamic analysis results of the crossbeam show that the
optimized structure improves the machine design accuracy and
that can be a good reference for designing all kinds of machine
tools.
analyzed underground farms arched tents supported by the
crane beams, the analysis showed deformation and stress
conditions of the arch supported wall affect the overall
structure analysis result, so the impact of the supported wall
should be added to Analysis [5].
Big span beam structure is complex, a range of
parameters are difficult to be obtained through experiments,
therefore, according to the characteristics of the structure,
this paper analyze and optimize the crossbeam of heavy NC
gantry moving boring & milling machine, it has certain
reference value to the design and analysis of large span
machine.
II. FINITE ELEMENT STATE ANALYSIS OF CROSSBEAM

Keywords- Gantry boring milling machine; crossbeam;
structural analysis; optimization
I. INTRODUCTION
With the rapid development of extreme manufacturing,
the large-scale of machine has become an inevitable trend.
Although national space steel structure developed rapidly,
the big span bearing beam for machine is still tiny. At
present, the researches of big span machine crossbeam are
not very much at home and abroad.
C.Yongqing made the finite element analysis of structure
for 2400t gantry crane with ANSYS software, and got the
stress and deformation of key component in a variety of
conditions. Meanwhile, he used sealing ring in crossbeam
webs and hole edge of lord lug to reduce the stress
concentration of hole edge, Canceled the lateral holes of
beam webs around to avoid stress concentration, increased
the lord lug board lower lug width and thickness to solve the
lord lug board stress concentration phenomenon [1];
Z.Dewen calculated beforehand arch degrees of bridge type
crane girders accurately based on the finite element method,
the method gave all sorts deflection calculation methods of
bridge type crane girders, and deduced Calculation formula
of the webs baiting arch degrees curve before the girder was
made[2]; F.Junlian used the optimization program to
optimize the main girder, proposed the research method of
the bridge crane girder structure analysis and optimal design
[3]; S.V.Sorokin analyzed and optimize the energy flow of
structure Composed by beam element[4]; K.M.Khuberyan
A. Structure ofHeavy Gantry Moving Boring & Milling
Mmachine
Host structure of heavy NC gantry moving boring &
milling machine generally includes lathe bed, the slippery
pillow, pillar, worktable etc mechanical parts. It is a multi-
function boring and milling machine, such as boring, milling,
drilling, tapping, and turning etc. This machine's workbench
is fixed and gantry framework moves. The general layout
form is gantry framework driven by double ac servo motor
moving on the slide seat, gantry framework (X axis) overall
moves, and a high-power multi-function slippery pillow
boring and milling head is deployed on gantry frame beam,
The slippery pillow boring and milling head slip board (the
Y axis) and the slippery pillow (the Z axis) are driven by ac
servo motor, beam (the W axis) is driven by double ac servo
motor, X, Y, W shaft guide use static pressure guide rails, Z
axis uses roll - slippery composite guide rail, The axis all are
closed-loop control, position detection is done by German
HEIDENHAIN grating ruler. It may realize the arbitrary
triad axis linkage with four feeding shaft.
Figure 1. Schematic diagram of gantry moving boring & milling machine

978-1-61284-088-8/11/$26.00 ©2011 IEEE 1586 12-14 August, 2011

B. Finite element calculation ofcrossbeam structure
This finite element calculation needs three aspects, first is
itself stiffness calculation, second is calculation state where
withstand the largest cutting force, beam deformation is
converted to tip displacement in this state, third is beam
deformation is converted to tip displacement under gravity
regardless of the cutting force.
This paper uses the before processor to established
directly beam calculation model, uses the APDL language of
Figure 3. Calculation state withstanding the largest cutting force
ANSYS to complete parameterized modeling, grid automatic
classification, and load position determination and applying, The biggest cutting force in tip is converted to guide
analyzes structural static of beam, and collects and disposes surface and is calculate. Beams were divided into 172 nodes,
automatically the results of analysis[6]. 138 rectangular units, 158 triangular units, 4 beam units.
1) Itself Stiffness: Due to the limit by structure size, Itself deformation is converted to tip displacement when
beam is commonly elongated cuboids, which makes beam withstand cutting force, the calculating results are listed in
deformation more bigger; moreover, cantilever length large Table II.
changes of beam axis cutting tools affect parts machining 3) Under gravity: Beam deformation is converted to tip
accuracy in the process of moving. Therefore, beam own displacement under gravity regardless of the cutting force.
structure is generally host system weakest link. The tip displacement and beam guide distortion are
Itself stiffness calculation condition of beam: Beam is
calculated in beams middle and end. Calculation results are
given force along the Y and Z direction and is given torque
around the X axis. Beam and pillar guide interface is shown in Table III.
processed according to the rigid bearing. C. Result analysis ofthe finite element calculation
The schemes for beam itself stiffness by the load is
The intensity and rigidity distribution of beam are
shown in Fig. 2.
acquired in every case based on linear static solution of finite
The paper uses finite element analysis software ANSYS
element mechanics model. According to itself stiffness
to calculate itself stiffness of beam in above figure load
calculation, the calculation withstanding the largest cutting
constraints, analysis results are shown in Table I.
force and only under gravity, quantitative influences of the
2) Under maximum cutting force: Calculation state
tip displacement produced by beam structure are obtained. it
withstanding the largest cutting force is shown in Fig.3. Py,
can be seen from the above finite element analysis results,
Px and Pz are three cutting components; Hmax is the largest
beam itself stiffness needs to be further improved, beam
machining height; Lmax is slippery pillow biggest route.
bending deformation and torsion deformation in itself are
Cutting force distribution proportions of tool tip are: Py,
very large, so the size and structure optimization design
Px. Pz=l: 0.5: 0.3=50KN: 25KN: 15KN. should be done.

TABLE II. PROTOTYPICAL ANALYSIS RESULTS WITH LARGEST

CUTTING FORCE

Schemes Displacement under Maximum Cutting Force(mm)

direction Y Z X

K1 0.1521 -0.01 0.1225

TABLE III. PROTOTYPICAL ANALYSIS RESULTS UNDER GRAVITY

Figure 2. Schemes for beam itself stiffness by the load
In the middle of beams In the end of beams
Schemes
Tip displacement (mm) Tip displacement(mm)
TABLE I. ANALYSIS RESULTS OF ITSELF STIFFNES
direction Y Z X Y Z X

Schemes Itself Stiffness K1 -0.0164 -0.0715 0 -0.0164 -0.0715 0.0085

Stiffness in Stiffness in Torsion rigidity
direction direction of Y direction ofZ around the X axis
(N/u) (N/u) (NM/rad) III. OPTIMIZATION DESIGN OF CROSSBEAM STRUCTURE
K1 596 1137 62.8
A. Size and structure optimization ofbeam
It can be seen from the above finite element analysis
results that static deformation is large, Y axis negative

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direction is 0.0164 mm. Beams static stiffness is far from 30.1 percent, which is show in Fig 5. k3 increases bending
meeting precision requirements of precision machine tools, beam and torsion board in contrast with k2, which makes its
Thus, beam should be redesigned. stiffness increase 11.5% in direction of y and 5.6%in direct
Maximum bending deformation of the structure of beam of z, the torsion stiffness increase 75.9%, yet the weight
is 0.1225 mm via analysis, considering processing cost and increased 1.5 tons.
the overall arrangement in the actual processing, the final 2) Under calculation state ( withstand the largest cutting
improvement schemes of beam are determined: Starting from force): kl and k2 calculated based on heightening type
beam's external, bending beam and twisting board should be stress conditions, k3 calculate according to k2 stress
increased. Beam 1 plus one bending beam 2 to resist to condition adopting 100% unloading form. So stiffness of k3
bending deformation, adds torsion plate 3 and below torsion beams is higher than kland k2. It is shown in Table V.
plate 4 to increase torsion rigidity of the beam 3) It can be seen:The affection of tip displacement in Y
Modified models are shown in Fig. 4. and Z direction is few, but the affection in X direction is
(a) is kl scheme: Beam were divided 490 nodes, 398 very large. The tip displacement of k2 and k3 beams is
rectangular plate units, 327 triangles plate units and 74 beam fewer than kl, and the tip displacement ofk3 is fewest.
units; Beam weights 132 tons.
(b) is k2 scheme: Beam were divided 419 nodes, 226
rectangular plate units, 614 triangles plate units and 102 TABLE IV. RESULTS COMPARE OF BEAM ITSELF STIFFNESS
beam units; Beam weights 18.5 tons.
(c) is k3 scheme: Increase bending beam and twisting Schemes Itself Stiffness
board based on the k2; Beam weights 19.9 tons. Stiffness in Stiffness in Torsion rigidity
Adjust and update relevant documents in accordance with direction direction of Y direction ofZ around the X axis
(N/u) (N/u) (NM/rad)
the above structure, and take into ANSYS to solve. The
results compared with the original data model are shown in K1 596 1137 62.8
Table IV , Table V and Table VI. K2 1041 1426 108.9

K3 1160 1505 191.5

TABLEV. RESULTS COMPARE UNDER MAXIMUM CUTTING FORCE

Schemes Displacement under Maximum Cutting Force(mm)

direction Y Z X

K1 0.1521 -0.01 0.1225

K2 0.1235 -0.0086 0.1150

K3 0.09375 -0.0049 0.1029

TABLE VI. RESULTS COMPARE UNDER GRAVITY

In the middle of beams In the end of beams

Schemes
Tip displacement (mm) Tip displacement(mm)
direction Y Z X Y Z X

K1 -0.0164 -0.0715 0 -0.0164 -0.0715 0.0085

K2 -0.0140 -0.0698 0 -0.0144 -0.0698 0.0073

K3 -0.0044 -0.0451 0 -0.0044 -0.450 0.0012

c. Final optimized structure ofbeam

Figure 4. Structure optimization diagram of beam
B. Optimization results analysis ofcross beam
According to the transformation and calculation of beam
structure and size, we can acquire the following conclusions:
1) ItselfstifJness ofk2 and k3 beams are higher than k1.
Calculation results are shown in table 4. Because K2 and k3
beams have larger section size than kl, its section increases
Left and right pillars of beam deploy separately a large
diameter cylinder to balance the weight of the beams, which
can eliminate slanting load caused by the different position
of Boring and milling head in the beam, and can ensure
stability and high precision of beam in feeding.
The upper guide adopts steel unloading guide to load the
weight of slider and the slippery pillow boring and milling
head of beam. The processing of front guide uses Pre
deformation processing method to overcome and offset

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deformation errors in the two direction produced by itself-
gravity and subversion torque when the slippery pillow
boring and milling head and beams slider is moving on front
guide. Through the above method, spindle and geometry
precision are kept good condition, the static precision and
dynamic processing precision of the slippery pillow boring
and milling head and accessories milling head are guaranteed
effectively.
IV. MODEL ANALYSIS OF MACHINE BEAM
Hypothesis it is ideal welded, original structure of beam
is the structure mixed plate and block. According to the
actual work situation, where contacts with 2 the guide is
considered as line constraint, the restrained two freedoms
UY, UZ serve as the boundary conditions of the entire model.
The first three modes are achieved through calculation.
The structure after static optimization conduct another
modal analysis, it can be found that each order natural
frequency has a slightly different in contrast with the original
natural frequency, because both have made a change in the
structure. Calculation results are shown in Table VII.
TABLE VII. NATURAL FREQUENCY COMPARISON OFOPTIMIZED
STRUCTURE AND ORIGINAL STRUCTURE
Prototype Improved Mode of
Direction
(HZ) Scheme(HZ) Vibration
Bend in the
first-order 249.95 272Al
direction of Y
Bend in the
second-order 302.68 304.34
direction of Z
Bend in the
third -order 319.50 333.39
direction of X
We can draw the following conclusion from the modal
analysis results of two kinds of structure:
The types of internal ribbed slab exert a tremendous
influence to the dynamic characteristics of beam. Low order
natural frequency and the quality of the beam increase
accordingly, along with the increase of the space of ribbed
slab.
From modal analysis results of optimization model, it can
be seen that local structures resettling traverse motor appear
partial vibration, because local structure stiffness is relative
weak, but the frequency is lesser, it need not consider.
However, the local link may cause fatigue damage of
structure, it can use appropriate reinforced beam to avoid.
The type of traverse motor is 1FT6 in the feeding
institution, its rotational speed is 1000-1500r/min, and
natural frequency is 16.7-25Hz, the fundamental frequency
obtained by modal analysis is 34.589 Hz in this structure,
working frequency of servo motor and fundamental
frequency are not in the same frequency band, thus this
structure will not occur resonance or violent vibration in the
process of operation.
Due to such structure wider in the directions of x and y
the influence of processing precision is not very large in the
previous order modes.
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The movement of beam parts is completed by ball-screw
driven by servo motor under the servo system, so the
vibration frequency of ball-screw will have a direct impact
on structure of beam. Pitch of ball-screw is 10mm, the
feeding speed is 12-24m/min, it can be calculated that
rotational speed is about 1200-2400r/min, and the excitation
frequency is between20 Hz and 40 Hz. Therefore, the ball-
screw working frequency well below the natural frequency,
so there is almost no influence on beam structure.
V. CONCLUSION
The finite element static analyses, dynamic analysis and
structural optimization design of crossbeam of XK2650 X
400 heavy NC gantry moving boring & milling machine are
completed in this paper. The optimized each order natural
frequency is far away from the machine working frequency
and motor working frequency, which can avoid effectively
the influence on the work precision of cutting tools due to
resonance and the fierce vibration. It shows the dynamic
properties of the optimized model can meet the requirement
and can improve the machine work precision.
ACKNOWLEDGMENTS
This work was supported by High-end CNC machine
tools and basic manufacturing equipment technology major
projects (2009ZX04002-042), National Natural Science
Foundation of China (51075106, 51005063, 50975066) and
the Key Program of Heilongjiang Province Natural Science
Foundation of China (No.zjg0702-01) and science and
Foundation for Youths of Heilongjiang (QC08C88) and
Technology item of Heilongjiang Provincial Education
Department (No.11531051, No.11551080).
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