Engineering Science and Technology, an International Journal 19 (2016) 1971–1984

Contents lists available at ScienceDirect

Engineering Science and Technology,

an International Journal
journal homepage: www.elsevier.com/locate/jestch

Short Communication

Static structural analysis of great five-axis turning–milling complex CNC

machine
C.C. Hong ⇑, Cheng-Long Chang, Chien-Yu Lin
Department of Mechanical Engineering, Hsiuping University of Science and Technology, Taichung 412-80, Taiwan, ROC

a r t i c l e i n f o a b s t r a c t

Article history: The design and analysis experiences of computer aided engineering (CAE) used in the heavy industry is
Received 22 April 2016 novel for conventional company before prepare going to execute the fourth industrial revolution. The
Revised 9 June 2016 research purpose is to provide a utilization results of computation and automation in the third industrial
Accepted 22 July 2016
revolution. The CAE with commercial software is used as the research method to analyze the linear static
Available online 1 August 2016
construction, stress and deformation for secondary shaft system, primary shaft system and machinery
bed in great five-axis turning–milling complex CNC machine. It is desirable to reduce most weight of
Keywords:
CNC machine and maintain good enough stress to resist external loads in the process of researches.
CAE
Static
The linear results and conclusion for static stresses and displacements of secondary shaft system, primary
Construction shaft system and machinery bed are obtained with the commercial computer software SOLIDWORKSÒ
Deformation 2014 simulation module.
CNC Ó 2016 Karabuk University. Publishing services by Elsevier B.V. This is an open access article under the CC
Machinery bed BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).

1. Introduction
Heavy industry machines usually modern designed in less cost,
time, manpower and with more efficient when compared with
conventional design ways. Uriarte et al. [11] presented the design,
principles and applications for heavy industry manufacturing
machines. There are some manufacturing means: cutting, turning
and milling etc., introduced by Black et al. [2] products at the low-
est cost are desired. For the general descriptions of five-axis turn-
ing–milling complex computer numerical control (CNC) machine,
Mao et al. [8] provided an automatic collection of machining preci-
sion for a CNC turn-mill machining center. Kara and Budak [6] used
an orthogonal turn-milling to optimize machining processes on a
multi-tasking CNC machine tool. Majerik and Jambo [9] used com-
puter commercial software CATIAÒ V5 to simulate tool-paths on
hard milling process. Bohez [3] presented the kinematic of five-
axis CNC machining center with the work piece by four axes: X-
axis, Y-axis, A-axis, B-axis and one Z-axis: tool. Wagner [13] used
the AUTOLISP program (a commercial AUTOCADÒ component) to
simulate the cutting tool path in the 5 axes CNC machining.
⇑ Corresponding author.
E-mail addresses: cchong@mail.hust.edu.tw (C.C. Hong), clchang@mail.hust.edu.
tw (C.-L. Chang), george@llmachinery.com.tw (C.-Y. Lin).
Peer review under responsibility of Karabuk University.
Doyle and Case [4] presented the CAE commercial software for
the students’ education in the manufacturing engineering. Zaeh
and Siedl [14] used finite element method (FEM) to simulate and
predict the machine tools in large deformation behavior. Mackerle
[7] reviewed the 1976–1996 analysis and simulation of machining
by using FEM. There are some commercial CAE software: genera-
tive structural analysis software of CATIAÒ, structural analysis soft-
ware of ANSYSÒ, simulation software of SOLIDWORKSÒ, simulation
software of CreoÒ, simulation software of InventorÒ, simulation
software of FreeCAD (an open-source), simulation software of NXTM
NastranÒ, simulation software of AbaqusÒ, composite analysis and
structural sizing software of HyperSizerÒ, NFX simulation software
of midasÒ etc. Vivekananda et al. [12] used commercial software
ANSYSÒ (one of the FEM codes) to compute the natural frequency
of vibration for ultrasonic assisted turning (UAT) machining
process.
Ananthavel et al. [1] used the numerical simulation software
(MatlabÒ/Simulink) to investigate the power transfer capacity sys-
tem. Mohammed et al. [10] used software ANSYS to simulate ther-
mal history for welding UNS S31803 duplex stainless steel joints.
Euan et al. [5] used the MatlabÒ graphical user interface (GUI) soft-
ware to simulate static cutting forces for ceramic milling tools. The
design and analysis experiences of CAE used in the heavy industry is
novel for conventional company before prepare going to execute
the fourth industrial revolution. The research purpose is to provide
a utilization results of computation and automation in the third

http://dx.doi.org/10.1016/j.jestch.2016.07.013
2215-0986/Ó 2016 Karabuk University. Publishing services by Elsevier B.V.
This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
1972 C.C. Hong et al. / Engineering Science and Technology, an International Journal 19 (2016) 1971–1984
Fig. 1. Great five-axis turning–milling complex CNC machine assembling 3D parts.
industrial revolution. For the construction of great five-axis turn-
ing–milling complex machine in this paper, the linear static stresses
and displacements of secondary shaft system, primary shaft system
and machinery bed of CNC machines are obtained with the SOLID-
WORKSÒ 2014 simulation module. The maximum values of stress
and displacement are provided to give a reference and prediction
for the future construction of complex CNC machine. In the
advanced future works, when the boundary condition is applied
to the calculating model, the nonlinear state of the contact surface
would be considered, which has a great influence on the calculation
results. In addition to gravity, other dynamic loads, such as inertial
force, cutting vibration and impact force, can be translated into sta-
tic loads, which can be applied to the calculation model.
2. Method of simulations
2.1. Mathematical model and software
In the linear static structural analysis without considering iner-
tial force, damping force and impact force, also the nonlinear state
of the contact surface would not be considered, a general matrix
equation of mathematical model is used in the computer program
to solve for stress and displacement results as follow,
½Mfug ¼ ff g
where ½M is material stiffness matrix, fug is displacement vector,
ff g is external load vector. The method of simulation with the soft-
ware SOLIDWORKSÒ simulation module is followed in its steps.
Step one, preparing and assembling all three dimensional parts
(3D) that wanted to be simulated. Step two, choosing the individual
materials of 3D parts that defined the properties wanted to be ana-
lyzed. Step three, setting up the corresponding boundary conditions
for the restrictions on the 3D parts. Step four, external loadings
applied on the 3D parts. Step five, mesh of grids generated for the
3D parts. Step six, computation. Step seven, displacement, strain
and stress results found.
2.2. Assembling 3D parts
To use the commercial CAE software and run the static results
for complex CNC machine, it is necessary to prepare the assem-
bling 3D parts of great five-axis turning–milling complex CNC
machine as shown in Fig. 1. The dimensions of main parts are pro-
vided respectively, for machinery bed is 8470 mm  1463 mm 
783 mm, for primary shaft system is 1190.5 mm  940 mm 
860 mm, for secondary shaft system is 1397 m  845 mm  1426
mm, for work piece is cylindrical column with diameter u950
mm and length 5000 mm. The positions of secondary shaft system
can be moved from 0 mm to 6900 mm, there are three locations
(0 mm, 4000 mm and 6900 mm) of positions used to computed
and analyzed for the CNC machine.
2.3. Materials of 3D parts
It is necessary to define the individual material of assembling
3D parts for great five-axis turning–milling complex CNC machine.
The materials of main parts are given, for machinery bed, shaft sys-
tems and work piece are cast iron. The yield stress of cast iron
ð1Þ
material is 275 MPa. To prevent failure in the CNC machine, the
value of working stress in each material of components should
under its yield stress value.
2.4. Boundary conditions of machinery bed
Five types of clamp (4, 8, 14, 20 and 36 positions) boundary con-
ditions of machinery bed are used to computed and analyzed for
the second principal axes of CNC machine locates at three kinds
of position (0 mm, 4000 mm and 6900 mm). Total 36 positions
 C.C. Hong et al. / Engineering Science and Technology, an International Journal 19 (2016) 1971–1984 1973

(a) Bottom view of 36 positions clamp boundary conditions

(b) Initial displacement and external gravity loads

Fig. 2. Total 36 positions clamp of machinery bed in CNC machine. (a) Bottom view of 36 positions clamp boundary conditions. (b) Initial displacement and external gravity
loads.

(18 positions at each side) clamp of machinery bed in CNC machine
is shown in Fig. 2 for secondary shaft system locates at 0 mm, typ-
ically. In Fig. 2(a), bottom view of 36 positions clamp boundary
conditions is shown. In Fig. 2(b), the initial displacement (displace-
ment is 0 mm at each position of clamps) and the external gravity
loads (acceleration of gravity 9.81 m/s2 perpendicular to X–Z
plane) are shown.
2.5. Convergence study of meshes
A typical mesh of grids with secondary shaft system at
4000 mm location for the CNC machine is shown in Fig. 3. To find
the more suitable number meshes used in the computation and
analyses for the CNC machine, it is necessary to make convergence
study of meshes. There are 200.00 mm, 160.00 mm, 155.00 mm,
1974 C.C. Hong et al. / Engineering Science and Technology, an International Journal 19 (2016) 1971–1984

Fig. 3. Typical mesh of grids for the CNC machine.

Table 1 sure external loads (10 MPa) on the machinery bed are considered.
Convergence results. Static stress and displacement results of total 36 positions clamp of
Maximum mesh grid sizes (mm) Maximum displacement values (mm) machinery bed are shown in Figs. 4(c) and (d), respectively. The
200.00 8.454
maximum value of stresses is 396 MPa and the maximum value
160.00 8.463 of displacements is 0.89 mm in the machinery bed. The maximum
155.00 8.465 value (396 MPa) of stress due to gravity force and uniform pressure
150.00 8.472 external loads (10 MPa) are greater than yield stress value
140.00 8.470
275 MPa, so the machinery bed are in un-safety condition. Do
not suggest the machinery bed to stand greater and over than
10 MPa external loads. Fortunately, the total actual gravity loads
150.00 mm and 140.00 mm of maximum size lengths of five type of primary shaft system, secondary shaft system, work piece and
meshes used to find the maximum displacement converged values end supporter upon the machinery bed are around 0.1 MPa
of machinery bed. (10 tons/m2), it is less than 10 MPa and can be considered in safety
condition.
3. Results and discussions
3.3. Static results due to gravity force of main parts
3.1. Convergence results
For the precision, all the gravity force loads of main parts in
Convergence results of maximum displacement values of total machinery bed, primary shaft system, secondary shaft system,
36 clamp positions machinery bed with secondary shaft system work piece and end supporter are considered. Static stress and dis-
at 0 mm location in CNC machine are listed in the Table 1. The placement results of total 36 positions clamp of machinery bed
maximum size length 150.00 mm of mesh grids can be considered (weight 13 tons) with secondary shaft system at three locations
in good convergence condition and used these grids to calculate of X axis: 0 mm, 4000 mm and 6900 mm in CNC machine due to
the stresses and displacements for further static computation with gravity force effect are shown in Figs. 5–7, respectively. When
the SOLIDWORKSÒ 2014 simulation module. the secondary shaft system located at X axis: 0 mm, the maximum
value of stresses is 154 MPa and the maximum value of displace-
3.2. Static results due to gravity force of machinery bed and external ments is 0.17 mm. When the secondary shaft system moved and
loads located at X axis: 4000 mm, the maximum value of stresses is
137 MPa and the maximum value of displacements is also
Firstly, only the machinery bed gravity force (weight 13 tons) 0.17 mm. In order to express even clear of the simulation results,
itself on the machinery bed are considered, static stress and dis- resultant displacement (URES) for chosen nine nodes at the bottom
placement results of total 36 positions clamp of machinery bed line of secondary shaft system is depicted with the curve picture as
are shown in Figs. 4(a) and (b), respectively. The maximum value shown in Fig. 6(c), they are linearly decreasing from value
of stresses is 2 MPa and the maximum value of displacements is 0.011 mm. When the secondary shaft system moved and located
0.0038 mm in the machinery bed. Secondly for the simplicity, the at X axis: 6900 mm, the maximum value of stresses is 129 MPa
machinery bed gravity forces (weight 13 tons) and uniform pres- and the maximum value of displacements is same as 0.17 mm.
 C.C. Hong et al. / Engineering Science and Technology, an International Journal 19 (2016) 1971–1984 1975

(a) Stress for machinery bed due to gravity force

(b) Displacement for machinery bed due to gravity force

Fig. 4. Stress and displacement for machinery bed due to gravity force and external loads. (a) Stress for machinery bed due to gravity force. (b) Displacement for machinery
bed due to gravity force. (c) Stress for machinery bed due to gravity force and external loads. (d) Displacement for machinery bed due to gravity force and external loads.

The maximum values of stress due to gravity force effect for sec- 3.4. Static maximum values for five types of clamp
ondary shaft system at X axis: 0 mm, 4000 mm and 6900 mm are
all smaller than yield stress value 275 MPa, so the CNC machine For secondary shaft system locates at X axis: 0 mm, the com-
can be considered in safety condition. pared results of static maximum stress and displacement for
1976 C.C. Hong et al. / Engineering Science and Technology, an International Journal 19 (2016) 1971–1984

(c) Stress for machinery bed due to gravity force and external loads

(d) Displacement for machinery bed due to gravity force and external loads
Fig. 4 (continued)

five types of clamp (36, 20, 14, 8 and 4 positions) boundary
conditions of machinery bed are shown in Tables 2 and 3,
respectively. The static maximum stress (154 MPa) and dis-
placement (0.17 mm) in total 36 positions clamp boundary con-
ditions of machinery bed are found in smaller values than the
others. The static stress and displacement for other four types
of clamp (20, 14, 8 and 4 positions) boundary conditions of
machinery bed are shown in Figs. 8–11 with enlarge amplifica-
tion scale, respectively.
3.5. Reduced weight for machinery bed
Usually it is desirable to reduce most weight of CNC machine
and maintain good enough stress to resist external loads. The
 C.C. Hong et al. / Engineering Science and Technology, an International Journal 19 (2016) 1971–1984 1977

(a) Stress for secondary shaft system at x axis: 0mm

(b) Displacement for secondary shaft system at x axis: 0mm

Fig. 5. Stress and displacement for secondary shaft system at X axis: 0 mm. (a) Stress for secondary shaft system at X axis: 0 mm (b) Displacement for secondary shaft system
at X axis: 0 mm.

reduced weight for machinery bed (weight 12 tons) with tunnel
type is shown in Fig. 12. The ribs in the two sides of bed are
removed, formed as a tunnel shape and reduced 1 ton weight.
Compared results of static stress and displacement in total 36 posi-
tions clamp for two types of machinery beds (weight 13 tons and
12 tons) with secondary shaft system at three locations of X axis:
0 mm, 4000 mm and 6900 mm in CNC machine due to gravity force
effect are shown in Tables 4 and 5, respectively. Also the maximum
values of stress due to gravity force effect for secondary shaft sys-
tem at X axis: 0 mm, 4000 mm and 6900 mm are all smaller than
yield stress value 275 MPa, so the two type’s beds of CNC machines
can be considered in safety condition.
1978 C.C. Hong et al. / Engineering Science and Technology, an International Journal 19 (2016) 1971–1984

(a) Stress for secondary shaft system at x axis: 4000mm

(b) Displacement for secondary shaft system at x axis: 4000mm

(c) Resultant displacement (URES) for chosen nodes of secondary shaft system
Fig. 6. Stress and displacement for secondary shaft system at X axis: 4000 mm. (a) Stress for secondary shaft system at X axis: 4000 mm. (b) Displacement for secondary shaft
system at X axis: 4000 mm (c) Resultant displacement (URES) for chosen nodes of secondary shaft system.
 C.C. Hong et al. / Engineering Science and Technology, an International Journal 19 (2016) 1971–1984 1979

(a) Stress for secondary shaft system at x axis: 6900mm

(b) Displacement for secondary shaft system at x axis: 6900mm

Fig. 7. Stress and displacement for secondary shaft system at X axis: 6900 mm. (a) Stress for secondary shaft system at X axis: 6900 mm. (b) Displacement for secondary shaft
system at X axis: 6900 mm.

Table 2
Compared static maximum stresses for five types of clamp.

Maximum stresses Clamp positions of bed

Total 36 Total 20 Total 14 Total 8 Total 4
154 MPa 157 MPa 155 MPa 159 MPa 191 MPa
1980 C.C. Hong et al. / Engineering Science and Technology, an International Journal 19 (2016) 1971–1984

Table 3
Compared static maximum displacements for five types of clamp.

Maximum displacements Clamp positions of bed

Total 36 Total 20 Total 14 Total 8 Total 4
0.17 mm 0.17 mm 0.18 mm 0.21 mm 0.49 mm

(a) Stress for total 20 clamp positions of bed

(b) Displacement for total 20 clamp positions of bed

Fig. 8. Stress and displacement for total 20 clamp positions of bed with amplification scale 4863. (a) Stress for total 20 clamp positions of bed. (b) Displacement for total 20
clamp positions of bed.
 C.C. Hong et al. / Engineering Science and Technology, an International Journal 19 (2016) 1971–1984 1981

(a) Stress for total 14 clamp positions of bed

(b) Displacement for total 14 clamp positions of bed

Fig. 9. Stress and displacement for total 14 clamp positions of bed with amplification scale 4714. (a) Stress for total 14 clamp positions of bed. (b) Displacement for total 14
clamp positions of bed.
1982 C.C. Hong et al. / Engineering Science and Technology, an International Journal 19 (2016) 1971–1984

(a) Stress for total 8 clamp positions of bed

(b) Displacement for total 8 clamp positions of bed

Fig. 10. Stress and displacement for total 8 clamp positions of bed with amplification scale 3934. (a) Stress for total 8 clamp positions of bed. (b) Displacement for total 8
clamp positions of bed.
 C.C. Hong et al. / Engineering Science and Technology, an International Journal 19 (2016) 1971–1984 1983

(a) Stress for total 4 clamp positions of bed

(b) Displacement for total 4 clamp positions of bed

Fig. 11. Stress and displacement for total 4 clamp positions of bed with amplification scale 1763. (a) Stress for total 4 clamp positions of bed. (b) Displacement for total 4
clamp positions of bed.
1984 C.C. Hong et al. / Engineering Science and Technology, an International Journal 19 (2016) 1971–1984

module. The static stress and displacement for other four types
of clamp boundary conditions of machinery bed are studied. It is
desirable to reduce most weight of CNC machine and maintain
good enough stress to resist external loads. The maximum values
of stress due to gravity force effect are all smaller than yield
stress value, so the CNC machine can be considered in safety
condition.

Acknowledgements

The completion of this paper was made possible by a grant

MOST 103-302-2-004 from Ministry of Science and Technology,
Taiwan, ROC.

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