Optimization Design of Machine Tool Beam based on Orthogonal Experiment

Abstract

To enhance the natural frequency of the machine tool beam system and ensure its structural performance, it is crucial to achieve a rational layout of rib structural characteristics. This study utilized the 3D design software SolidWorks for the construction of a three-dimensional model of the machine tool beam, followed by comprehensive modal analysis using Ansys finite element analysis software. In assessing the design merits of the machine tool beam, this research selected the natural frequency as the key objective function and considered initial design variables such as the number of rib segments, rib thickness, rib width, and intermediate span distance for systematic multi-objective optimization design. To determine the optimal combination of design variables, orthogonal experimental design was employed, comprising four factors and three levels. Through rigorous data analysis methods, critical factors influencing beam performance and their optimal levels were identified, thereby establishing an optimal experimental simulation scheme. Subsequent to obtaining the optimal solution, this study further developed a response surface regression model aimed at achieving lightweight design while maintaining static and dynamic beam performance, thereby balancing quality and performance. By employing this research methodology, the study not only provides a scientific basis for optimizing the design of machine tool beams but also offers valuable insights for research and practice in related fields. Results indicate that the optimal configuration-"outer wall thickness of 48mm, rib thickness of 36mm, rib width of 37mm, 9 segments, and intermediate support distance of 690mm"-improved the first-order natural frequency by 23% compared to the original design. Compared to the optimized data post orthogonal experiments, the mass was reduced by 3.6%. This study expands the application scope of orthogonal experimental design and response surface testing, providing beneficial methodological references for the design of other machine tool components.