STUDY OF STRUCTURAL OPTIMIZATION ON RECONFIGURABLE …€¦ · The solution to be obtained is not a single optimum solution, but an optimum set of optimum parts that can be reconfigured

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International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 8, August 2017, pp. 473–480, Article ID: IJMET_08_08_053

Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=8

ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication Scopus Indexed

STUDY OF STRUCTURAL OPTIMIZATION ON

RECONFIGURABLE MACHINETOOL

A.Sathesh kumar, M.Karthick, D.L.Belgin Paul and K. Karthik,

Assistant Professor, Department of Mechanical Engineering,

Vel tech Dr.RR & Dr.SR University, Chennai, India

ABSTRACT

This work proposes structural optimization of Reconfigurable Machine Tool that

considers design reconfigurability in the configurable machine tool. The ability of a

configurable system to be reconfigured allows it to perform well under different

considered loading conditions in different configurations. Performance is measured in

this paper as machining accuracy, subject to structural constraints. The ADAMS,

Ansys, MATLAB/SIMULINK softwares are usedto enable the component level

optimization. In this paper the Configurable Machine tool will be taken for

Optimization process and to achieve the Optimized Components to enable

Reconfigurability in Configurable machine tool components. The algorithm for

Component level optimization is developed in the MATLAB/SIMULINK software.

Keywords: Structural Optimization, Reconfigurable Machine Tool, Anasys.

Cite this Article: A.Sathesh kumar, M.Karthick, D.L.Belgin Paul and K. Karthik,

Study of Structural Optimization on Reconfigurable Machine tool, International

Journal of Mechanical Engineering and Technology 8(8), 2017,pp. 473–480.

http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=8

1. INTRODUCTION

Typically, structural design optimization is performed by only considering the structural

performance of the design in the optimization process for a single load case. Conventional

structural performance metrics are stress, mass, deformation, or natural frequencies. Another

important aspect to be considered in structural optimization in configurable machine system

and is loading condition variation. In this work, we propose a new design optimization

framework that deals with structural optimization considering many different loading

conditions arises with configuration variations. These loading conditions are assumed to never

be applied simultaneously to the structure. The goal is not to make the system insensitive, but

to make it reconfigurable such that it can deal with these various loading conditions well.

While robust design is a passive response to different loading conditions, design for

reconfigurability is an active response. The incorporation of this reconfigurability into

structural design can lead to significant benefits such as reduced manufacturing cost.

Study of Structural Optimization on Reconfigurable Machine tool


An overview depicting the procedure used to produce an optimal reconfigurable design

introduced in this paper is shown in Fig. 1.1. This illustrative example is of a truss structure

subject to various loading conditions. The solution to be obtained is not a single optimum

solution, but an optimum set of optimum parts that can be reconfigured to form several

different designs.

In this procedure for illustrative purpose [1], a reconfigurable two dimensional truss

structure is designed based on structural performance and the reconfigurability of the

structure. The result of the optimization routine is an optimum set of optimum parts based on

the requirements defined in the problem statement.

The motivation for incorporating reconfigurability into structural design in this paper is to

account for various loading conditions experienced in the application of a specific structural

design. More specifically, in this work design reconfigurability allows for a structural design

to accommodate loading variation.

Figure 1.1 Optimization for reconfigurability procedure

A.Sathesh kumar, M.Karthick, D.L.Belgin Paul and K. Karthik


Conventionally, structural design optimization is typically done by considering one set of

requirements to create a customized structural design. The worst of worst cases will be

considering in the optimal criteria I. Another method of performing structural optimization is

to consider several sets of requirements and design a structure which performs well for the set

of requirements considered, a design envelope. In this paper, this method of structural design

optimization is referred to as “Envelope method” optimization. Structural design optimization

for reconfigurability, in which a single set of components is designed to be reconfigured for

various structural requirements, is referred to as “Reconfigurability” optimization. These

structural design optimization methods are illustrated in Fig. 1 custom designs are created for

each considered load case, an enveloping design is created for both load cases, and a set of

structural components are created which can be reconfigured into feasible structural designs

for each load case considered. The magnitudes of the cross-sectional areas of the truss

structure elements are depicted as the thickness of the lines in Fig. 1.2.Figure 1.2 Three

structural design optimization methods considering different loading conditions

The goal is to design a set of module that can be reconfigured to form various machine

tool configurations which can each accommodate different machining requirements. The set

of optimum modules used to build these varying configurable machines tool is obtained

through reconfigurability consideration of accuracy/machining cost. We consider an

important metric to represent the performance of the machine design: Accuracy.

Manufacturing cost is chosen to be the metric for this project because the structural

designs being optimized are assumed to be used in the private sector. The goal sought by the

private sector is to improve profit margin. The consideration of reconfigurability in design

allows for a reduction in costs. This reduction in costs is made possible because the

manufacturer can mass-produce one set of components which can satisfy many different

customer requirements rather than manufacturing a custom designed machine tool for each

customer need. This ability to manufacture few custom designs and satisfy many customer



requirements allows the manufacturer to reduce costs. This in turn improves the profit margin

of the manufacturer and is integral to the health of a private business. Design for

reconfigurability can help private industry reduce costs by reducing manufacturing costs for a

machine by designing a reconfigurable machine module set that can handle various machining

configurations.

A more general definition for design reconfigurability presented in this paper is discussed

here. A reconfigurable machine is composed of modules that are interchangeable and can be

configured to create various structural designs. Structural reconfigurability is the ability of the

configuration to be modified in order to respond to different machining requirement such as

milling operation, lathe operation, drilling operation. In the case of the machine tool structure

elements considered in this paper, a module is an element in the “optimal” set of structural

elements. Reconfiguration can be done by rearrange the modular into newer combination.

assemblability, and modularity were considered in the decomposition optimization

problem.

It can be seen in the literature survey that while research has been done on structural

topology optimization as well as topics such as modularity, no research has been done on

structural topology optimization considering design reconfigurability, that too in machine

tools, it is newer.

The goal of this research is to investigate the manufacturing cost benefits resulting from

the incorporation of reconfigurability into structural design by studying the effects of design

reconfigurability in configurable machine tools.

[1]This paper presents methodologies for developing an intelligent CAD system assisting

in analysis and design of reconfigurable special machines. It describes a procedure for

determining feasibility of utilizing these machines for a given part and presents a model for

developing an intelligent CAD system. The system analyzes geometrical and topological

information of the given part to determine possibility of the part being produced by

reconfigurable special machines from a technical point of view. Also feasibility of the process

from a economical point of view is analyzed. Then the system determines proper positioning

of the part considering details of machining features and operations needed. This involves

determination of operation types, cutting tools and the number of working stations needed.

Upon completion of this stage the overall layout of the machine and machining equipment

required are determined.

A gradient based optimization technique based on the method of feasible directions [24]

has been used to solve the optimization problems at levels 1 and 2. Structural sensitivity

analysis is performed using exact analytical expressions. Aerodynamic sensitivity analysis is

performed through direct differentiation of the discretized governing differential equations,

which is briefly described below.

2. PROBLEM FORMULATION

It describes the multilevel decomposition technique and the formulation of the aircraft design

problem using this technique. The multilevel decomposition procedure is illustrated through a

two-level formulation. Each level is a multi-objective optimization problem characterized by

a vector of objective functions, constraints and design variables. During optimization at a

particular level, it is essential to maintain the objective functions and design variables of

lower levels close to their optimum values. Therefore, constraints are imposed on the

perturbations to the lower level objective functions and design variables to prevent significant

changes. These parameters are called optimal sensitivity derivatives, and they establish the

necessary link between the various levels of optimization. The multilevel decomposition

procedure is outlined below.



In general, an aerodynamic performance coefficient, Cj, depends on the steady-state flow variables,

Q*, the vector of computational grid coordinates, X, and, sometimes, explicitly on the vector of

independent design variables, ¢. Mathematically,

Since the optimization process requires several evaluations of the objective function and

the constraints before an optimum design is obtained, the process can be very expensive if

actual analyses are performed for each function evaluation. The objective function and

constraints at levels 1 and 2 are, therefore, approximated using a two-point exponential

approximation [28] based on the

3. DESIGN METHOD DESIGN METHODOLOGY



Figure 4.1 Design Methodology

The fig 4.1 shows the basic methodology of structural optimization of reconfigurable

machine tool in that a set of components for the different configuration are taken, these

components are analyzed and optimized to satisfy different configuration.

The satisfied components are taken separately and not-satisfied components are

considered for optimization based on gradient based optimizer to satisfy configuration

requirement of reconfigurable machine tool.

Where F is the function that is being approximated, ¢o is the old design variable vector

and ϕ, Pi is the new design vector. The parameter p~ is used to control the approximation. For

Pi = 1, the approximation reduces to a first order Taylor expansion. For Pi = -1, the

approximation reduces to a reciprocal Taylor expansion. The parameter p~ is constrained to

Check for

component

design

Requiremen



assume values between -1 and 1. A move limit, typically defined as the maximum fractional

change of each design variable value, is imposed as upper and lower bounds on each design

variable ¢~ to control the validity of the approximation.

4. RESULT AND DISCUSSION

The structural optimization for reconfigurability in machine tool is modeled in CAD software

CATIA and exported to the ADAMS there the joint forces of the Machine tool will be

analyzed and the Reconfigurable machine tool model is modeled in Ansys based on the

parametric modeling concepts, and the structural, analysis of the Reconfigurable machine tool

is analyzed using the ANSYS software. Based on the results of machine tool system the

optimization of the machine tool components for the desired requirements are identified and

the parameter based optimization are carried out to get the optimized RMT components for

achieving reconfigurability in machine tool component. For the automation of Optimization

process the Co-simulation is carried between Ansys/MATLAB SIMULINK, the Algorithm is

developed in MATLAB.

5. CONCULATIONS

The Reconfigurable machine tool model is modeled in Ansys based on the parametric

modeling concepts, and the structural, analysis of the Reconfigurable machine tool is

analyzed using the ANSYS software. Based on the results of machine tool system the

optimization of the machine tool components for the desired requirements are identified and

the parameter based optimization are carried out to get the optimized RMT components for

achieving reconfigurability in machine tool component.

For the automation of Optimization process the Co-simulation is carried between

Ansys/MATLAB SIMULINK, the Algorithm is developed in MATLAB.

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STUDY OF STRUCTURAL OPTIMIZATION ON RECONFIGURABLE …€¦ · The solution to be obtained is not a single optimum solution, but an optimum set of optimum parts that can be reconfigured