Enhancing Five-Axis Machine Tool Performance Through ESG-Based Design Optimization

Abstract

Today’s economic environment, the machine tool industry continually focuses on enhancing performance while reducing costs, conserving energy, and minimizing environmental impacts. This study employs a CAD-generated virtual model to assess the performance of key components in a 5-axis machine tool. The primary focus of this work on machine components' optimization design is to enhance machining performance, addressing both static and modal aspects generally leading to structural integrity of the machine and consumption conservation of energy. Initially, the modal impact experiments carried out on machine tool are verified by the mechanical numerical code to further carry out novel tests. Modal frequency differences (2.4–6.7%), as revealed by comparative analysis, validate the accuracy of the model setup and boundary conditions within a 10% threshold, allowing for the development of novel studies with accepted discrepancies. Then density-based optimization approach is employed to redesign the machine tools, aiming to raise the intrinsic oscillation frequency of the structure and minimize structural deformation from 0.021957 to 0.020864 µm respectively for the final optimized tool turret. After this, the model is forwarded for structural verification. This approach introduces a design-for-remanufacturing strategy, enhancing existing products by improving functionality and rectifying damaged components. Such optimization leads to lightweight structures and requires less material for reproducing parts. With the increasing demand in ESG (environmental, social, and governance) investments and emphasis for the potential of substantial energy savings through lattice optimization. The potential for substantial energy savings and reduction in environmental effects by optimization of a five-axis machine tool with utilization of ESG factors in considerations. The lattice optimization of machine components led to a 64.24% reduction in energy consumption, demonstrating the feasibility and benefits of integrating ESG principles into machine tool design.