Structural Design and Optimization of the Crossbeam of a Computer Numerical Controlled Milling-Machine Tool Using Sensitivity Theory and NSGA-II Algorithm

The crossbeam plays a vital role in computer numerical controlled milling machines, especially in machines with a gantry structure, as it directly influences the machining precision. In this study, a machine tool crossbeam was designed, and the modal frequency of the crossbeam was analyzed using the finite element model (FEM) analysis. In the improved structure obtained through FEM analysis, the X-type structure of the internal unit of the crossbeam was replaced by an O-type structure. The specific structure dimensions were further optimized using a neural-network algorithm and a nondominated sorting genetic algorithm. Finally, we calculated the effect of each crossbeam dimension on the mass, deformation, and frequency in a sensitivity analysis. After optimizing the crossbeam dimensions with respect to deformation, modal frequency, and mass, the structural characteristics of the original and optimized crossbeams were compared. After optimization, the mass and deformation were reduced by 7.45% and 3.08%, respectively, and the modal frequency was increased by 0.42%. These results confirm that the optimization improved the performance of the crossbeam structure.