Multi-procedure design optimization and analysis of mesoscale machine tools

Conventional machine tools are being miniaturized because of the technical and economic advantages that this approach produces. Apart from these issues, the response time for marketing mesoscale machine tools is growing shorter. Thus, further development in this area will require a systematic design scheme to reduce subjectivity at the early design stage. This paper covers the structural optimization of a miniaturized milling machine using an integrated design strategy based on individual modeling and simulations of key parameters, such as volumetric error and machine working space, as well as static, thermal, and dynamic stiffness. This integrated approach was developed using analytical methods and then validated experimentally. Individual computations based on the mathematical model were carried out to produce a penalty function for the miniaturized milling machine that was then used to determine the optimal structure. This paper also discusses the sensitivity of weighting factors to determine which weighting factor is the most effective in an optimal solution. This study contributes to the development of more reliable mesoscale machine tools.