Proceedings of the 2017 IEEE International Conference on Applied System Innovation

IEEE-ICASI 2017 - Meen, Prior & Lam (Eds)

Study on the Strength of Composite Material for CNC Grinder Base Structure

Jui-Chang Lin 1, a, Cheng-Jen Lin 2,b

1
Department of Mechanical Design Engineering, National Formosa University, Yunlin 632, Taiwan
2
Institute of Mechanical and Electro-Mechanical Engineering, Department of Power Mechanical Engineering National Formosa
University, Yunlin632, Taiwan

a
nhit100@gmail.com, blcj@nfu.edu.tw

Abstract finally obtain the numerical solution. ABAQUS, finite element

In this study, it is possible to find a suitable composite
material for the strength of the composite foundation of CNC
grinding machine to replace the use of metal base. To reduce
the weight of CNC grinding machine and can increase its
seismic capacity. The main points of this study are: 1.
Structural stiffness analysis, stress and deformation of the
structure caused by the external load distribution of the CNC
machine. 2. Vibration frequency analysis, analysis of the
natural frequency of grinding machine will be avoided
resonance.
The study result appears as following, max value of
equivalent stress and average amount of displacement in
structural rigidity analysis are 0.67(Mpa) and 0.92(μm). And
modal analysis compared with the experimental, the average
error percentage was less than 10% of parts. The whole
structure percentage error does not exceed 3%, shows the
results of analysis and practical percussion data conformance
with nice, and has its reference value in the structural design
phase.
Key words: CNC Grinder Machine; Optimized Design；
Equivalent Stress；Vibration Frequency Analysis
Introduction
Based on practical operation, structural design, assembly
errors, and component machining problems play dominant role
in the accuracy of CNC machine. The structural vibration and
deformation have influence on CNC machine structure. That’s
because the strength, caused by improper reduction weigh, is
insufficient. As the machine is operated, some components of
the machine shake unavoidably, and it may lead to structural
resonance under some conditions, making the quality of
machining different. Therefore, it is necessary for structural
design of CNC grinding machine to carry out analysis of
experimental mode and finite element.
The improvement of the structural design errors, the
avoidance of the vibration frequency and the structural rigid
problems are of great importance task. FEM, a numerical
solution to engineering problem analysis, is currently one of
the analytic approaches. It is used to analyze the object which
was meshed and cut into appropriate size, number, and shape.
Combined with the force conditions, material properties as
well as the boundary conditions, the basic theoretical
principles (mainly elastic-plastic theory) and limited
cumulative iterations are applied to solve the element, and then
analysis software, is widely used in automobiles, civil
engineering, aerospace, and mechanical industries. A variety
of mechanics problems such as linear structure, non-linear
material stress and strain with vibration and deformation could
also be analyzed by ABAQUS/CAE. [1-4]
Vibration mode theory
Mechanical systems usually consist of several parts, and the
interaction does exist mutually. To study the vibration
characteristics of the actual mechanical system, a simpler
physical model is represented. Mechanics or mathematical
theorems are applied in order to set up the physical model
expression. Usually, a simple vibration system covers (1)
spring or elastomer of stored potential energy; (2) the mass or
inertia of stored kinetic energy; or (3) consumption of energy
damping. As general structure of the vibration system could
not be simplified to a point mass, the system will be considered
infinite degrees of freedom on the continuum. The FEM is
used to solve equation of motion or equations of force for the
complicated structure.
Vibration is the object which is viewed as a reference point,
and it moved back and forth with a small range of movement
under the static equilibrium. Consequently, the vibration of the
object is on a regular basis cycle of movement. Instead of what
we called vibration, four-bar linkage, slide-crank, swing, and
other periodic motion are only seen as problems inside the
dynamic system. Generally speaking, the vibration can be
divided into two types: free vibration and forced vibration. By
definition, free vibration system is generated by the vibration
exciting force in the initial conditions, or after the abolition of
the existing external vibration. On the contrary, forced
vibration is caused by periodically or intermittently external
forces. The two types of vibration can be either a damping or
undamped vibration; therefore, friction effect in the undamped
vibration system is ignored. Although it keeps the vibration,
the internal friction and external friction actually do exist; that
is to say, all objects are damping vibration. Owing to the
structure shape, size, material properties and even the
boundary conditions of the structure, frequency is variable.
Mode parameter is unique, constant, and it can be viewed as
the characteristics of the system.
FEM simulation analysis of base structure
Based on the results of the percussion experiment, the * .x_t
model of CNC grinding machine structure will be simplified to
the finite element analysis software. In this study, ABAQUS

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Proceedings of the 2017 IEEE International Conference on Applied System Innovation
IEEE-ICASI 2017 - Meen, Prior & Lam (Eds)

analysis software will be used to simulate the vibration
frequency model. The analysis of the ABAQUS software for
the metal casting base and the composite base will be carried
out in accordance with the following procedure:
1. First, after some simplified procedures, convert the CNC
structure to *. x_t file and import ABAQUS analysis
software.
2. Set the mechanical properties of the material used. Because
of this study is the vibration modal analysis and stress
analysis, the need for material density, elastic modulus and
Poisson’s ratio. The materials used in this study are mainly
carbon steel, gray cast iron and composite materials, the
mechanical properties of these materials are listed in
Table1~3.
3. Finite element method to simulate the mechanical
properties of the import model, and the frequency response
was actual execution to verify the simulation result. The
result will show where the weakness of grinding machine
structure is, and avoid resonance phenomenon when
spindle rotating. The structure of CNC grinding machine
mesh was shown in Fig. 1.
TABLE 1
The mechanical properties of Medium carbon-Steel material.
Material Medium carbon-steel
Density (ton/mm3) 7.89E-9
Young’s modulus (Gpa) 200
Poisson’s ratio 0.3
grinding operation is very small and far less than the yielding
strength of material. However, the resonance effect caused by
the natural frequency of the elements should not be neglected.
The experiment of base structure
In order to understand the vibration of CNC grinding
machine base, this study is now for the cast-iron base and
composite base for experimental modal analysis. The
specifications of the experimental equipment are shown in
Table 4. The experiment uses a spectrum analyzer,
accelerometer, hammers and computers, connects the
accelerometer and the hammer to the spectrum analyzer, and
the computer is connected to the spectrum analyzer. The
magnetic seat, which carry the accelerometer to adsorb on
pre-planned locations of the CNC machine base. And then use
the hammer to tap the base structure to stimulate the vibration,
the accelerometer will be able to measure the vibration
parameters. The composite base and cast-iron base structure
were shown in Fig. 2 and Fig.3 respectively.
TABLE 4
Experimental equipment and specifications.
Experiment Equipment Types
Spectrum Analyzer B&K, model：3560C
Three – Axis Accelerometer B&K, model：4506B
Knocking Hammer B&K,model：8208(51771)

TABLE 2
The mechanical properties of cast-iron material.
Material Cast iron (FC300)
Density (ton/mm3) 7.2E-9
Young’s modulus (Gpa) 110
Poisson’s ratio 0.28
yielding strength (MPa) 200
Fig. 2 CNC machine Base of Composite Material.
TABLE 3
The mechanical properties of Composite material.
Material Composite-Material
Density (ton/mm3) 2.4E-9
Young’s modulus (Gpa) 30~45
Poisson’s ratio 0.28

Fig.3 CNC machine base of cast- iron Material.

The data was analyzed by a spectrum analyzer and recorded

Fig. 1 CNC grinding machine base mesh.
About the simulation of stress, max value of equivalent
stress and average amount of displacement in structural
rigidity analysis are 0.67(Mpa) and 0.92(μm). Generally, the
cutting force compare with many machine tools, the stress of
in a computer. After the data collection, the *.x_t file of base
model would convert into a * .stl file to import the Mescope
analysis software for vibration-modal analysis.
After the completion of experiment, all of experimental data
and the model of base would import into Mescope to execute
post processing. The Fig. 4 showed the model of composite
base and reveals the placement of sensor on composite base.
By Mescope aggregated all experimental data of composite
base, the outcome of frequency domain was shown in Fig. 5.

524 - ISBN 978-1-5090-4897-7

 Proceedings of the 2017 IEEE International Conference on Applied System Innovation
IEEE-ICASI 2017 - Meen, Prior & Lam (Eds)

Composite base:
Base on the principle of experiment, this work
cross-comparison the data of experiment and simulation, and
shown the error in table 5. In term of the frequency that could
be appropriate correspondence, besides the lowest frequency,
the errors of other modal frequency were under 4%. Between
experiment and simulation result, there were some modal
frequency could not be appropriate correspondence. The
reasons speculated that have some differences between import
model and actual product, or the constrain conditions setting is
incomplete in simulation process.
Cast-iron base:
Fig. 4 The model of composite base displayed in Mescope. The same as the analysis of composite base, the outcome of
experiment and simulation data of cast-iron base was
concluded in table 6. Whether the results of experimental or
simulated, in a similar frequency range, the modal quantity of
cast-iron base is more than composite base, and compared the
lowest resonance frequency, cast-iron base is lower than
composite base.
Table 5
The experiment and simulation result of composite base.
modal Experiment(Hz) FEM simulation(Hz) error(%)
1 49.6 83.466 68.3
2 117 150.36 2.85
3 290.9 302.1 3.85
4 355.7 350.16 1.66
5 446.9 450.78 0.87
Fig. 5 The experimental result of composite base by mean of 6 614.8 613.73 0.18
Mescope. 7 748.6 737.59 1.47

To undergo the same experimental procedure of composite TABLE 6

base, the Fig. 6 exhibited the model of cast-iron base and The experiment and simulation result of cast-iron base.
sensor positions which shown in Mescope. Finally, Mescope modal Experiment(Hz) FEM simulation (Hz) error(%)
compiled the experimental data, and shown the frequency 1 34.4 47.608 38.40
domain result of cast-iron base in Fig. 7. 2 95.7 51.245 11.37
3 123 84.819 8.53
4 160 112.51 12.67
5 237 180.27 4.17
6 277 227.11 3.22
7 322 253.77 0.09
8 414 285.91 0.15

Fig. 6 The model of cast-iron base displayed in Mescope.
Conclusion
To sum up the result of experimental or simulated, the
principle purpose of this work is to understand the diversity of
cast-iron base and composite base. The results of the modal
analysis of cast-iron base and composite base will be described
below.
1. In lower frequency range, the composite base would have
slightly ability to suppress the resonance phenomena.
2. The experimental result shows, the composite base less
likely to cause resonance behavior in interesting frequency
range.
3. The minimum frequency error up to 68.3% in composite
base, this outcome speculated there was large and uneven
situation in composite base, after all, homogeneous
assumption was tacitly agree in the simulation process.

Fig. 7 The experimental result of cast-iron base by mean of References

Mescope. [1] Ramezanali Mahdavinejad, , Finite element analysis of
Results and Discussion machine and workpiece instability in turning, International
Journal of Machine Tools & Manufacture, Vol.45, pp.

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Proceedings of the 2017 IEEE International Conference on Applied System Innovation
IEEE-ICASI 2017 - Meen, Prior & Lam (Eds)

753-760,2005
[2] J. A. Ewing, and Humfrey, J. C., ”The Fracture of Metals
under Rapid Alterations of Stress,” Philosophical Transaction
of the Royal Society, London, Vol. A200, 1903, pp. 241-250.
[3] J. C. Newman, Jr., "A Finite Element Analysis of Crack
Growth under Monotonic and Cyclic Loading," ASTM STP
637, pp.56-80,1977.
[4] N. A. Fleck, "Finite Element Analysis of Plasticity-Induced
Crack Closure under Plane Strain Conditions," Engineering
Fracture Mechanics, Vol. 25, No. 4, pp.441-449, 1986.

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