applied

sciences
Article
Investigation of the Machining Stability of a Milling
Machine with Hybrid Guideway Systems
Jui-Pin Hung 1, *, Wei-Zhu Lin 1,2 , Yong-Jun Chen 1 and Tzou-Lung Luo 2
1 Graduate Institute of Precision Manufacturing, National Chin-Yi University of Technology, Taichung 41170,
Taiwan; weiJun@itri.org.tw (W.-Z.L.); isaak836@icloud.com (Y.-J.C.)
2 Intelligent Machine Tool Technology Center, ITRI Central Region Campus, Taichung 54041, Taiwan;
tzuolianglo@itri.org.tw
* Correspondence: hungjp@ncut.edu.tw; Tel.: +886-4-2392-4505 (ext. 7181); Fax: 886-4-2392-5714

Academic Editor: Chih Jer Lin

Received: 29 November 2015; Accepted: 23 February 2016; Published: 8 March 2016

Abstract: This study was aimed to investigate the machining stability of a horizontal milling machine
with hybrid guideway systems by finite element method. To this purpose, we first created finite
element model of the milling machine with the introduction of the contact stiffness defined at the
sliding and rolling interfaces, respectively. Also, the motorized built-in spindle model was created
and implemented in the whole machine model. Results of finite element simulations reveal that
linear guides with different preloads greatly affect the dynamic responses and machining stability of
the horizontal milling machine. The critical cutting depth predicted at the vibration mode associated
with the machine tool structure is about 10 mm and 25 mm in the X and Y direction, respectively,
while the cutting depth predicted at the vibration mode associated with the spindle structure is about
6.0 mm. Also, the machining stability can be increased when the preload of linear roller guides of the
feeding mechanism is changed from lower to higher amount.

Keywords: dynamic compliance; machining stability; hybrid guideways

1. Introduction
For satisfying multipurpose or specific industrial applications, most of the modern milling
machine centers nowadays have been designed and constructed by different modularized main
components [1]. In the configuration of the machine tool, the arrangement of linear feeding mechanism
plays an important role in determining machining performance because the various linear elements
or other joints are weaker links of different structural components [2,3]. Although modularized
design concept brings various machine configurations under consideration, evaluation of dynamic
performance of the candidates that can satisfy the required performance is a perquisite for fabricating
the prototype [4,5]. However, the feeding mechanism of the control axis has been verified to
greatly affect the structural dynamic characteristics and machining stability [6]. The joints in the
guideway system cannot be treated as a rigid interface; on the contrary, they form weak links between
components and greatly affect the overall structural characteristics of the assembled machine [7,8].
As a consequence, the modeling of an interface and the identification of the interfacial characteristics
are of importance in the dynamic analysis of a machine tool structure.
Currently, the horizontal milling machine with moving column has been constructed to achieve
multiple machining functions. The configuration of the feeding mechanism is considered a dominant
role for innovative design of such kind of machines. Generally, linear guides with rolling balls are
appropriate for light duty milling machines, while linear roller guide moduli or sliding guideway
systems were adopted in heavy duty milling machine to undertake more loads in machining.
Essentially, each of the various guideway systems possesses different kinematical and dynamic

Appl. Sci. 2016, 6, 76; doi:10.3390/app6030076 www.mdpi.com/journal/applsci

Appl. Sci. 2016, 6, 76 2 of 12

properties, which may thus bring the machine tool to demonstrate different dynamic performances.
Research studies [9,10] have shown that a rolling guide exhibits different vibration characteristics
depending on preloaded amount. Regarding the sliding contact guide, the contact stiffness of a
sliding surface is the function of surface finish, pairing of contact material, and interface pressure
distribution [11]. The interface pressure was also verified to be an important factor affecting the contact
stiffness and the machining performance [12].
The purpose of this study was to analyze the machining stability of a horizontal milling machine
with hybrid guideway systems which were assembled with linear roller guides and sliding guides with
coated antifriction layers. Currently, the finite element approach has been recognized as an effective
tool in modeling the machine tool, which can accurately predict the dynamic behavior of the prototype
designs without physically building any parts. This approach of designing prototype machines in
software has been termed virtual prototyping [13,14]. To be a realistic model for assessing the frequency
responses of the milling machine, a finite element model incorporating the machine frame with a
spindle unit was a prerequisite. Using the FE modeling approach, Sulitka et al., [15,16] demonstrated
the dynamic compliance of the spindle to vary with the changing of the machine configuration. Various
factors, such as the spindle bearing preload or structural geometry, influencing the FRFs at the tool
tip were also investigated [17,18]. The optimization of the machine tool design has been studied by
incorporating the FE models for full machine analyses with the consideration of machining stability
in process [19,20]. Studies of Mousseigne et al., [21,22] found the variation of the tool point dynamic
response with the change of milling, which further caused great influences on the stability lobe curves.
Their study also suggested that a precise estimation of the natural frequencies is of importance for
lessening the uncertainty of the stability lobe curves.
The milling machine discussed in this study was driven on hybrid guideway systems which were
assembled with a linear roller guide and a sliding guide with coated antifriction layers. In creating
the finite element models of the milling machine, apart from mechanical frame structure, the sliding
guides and roller guides were also modeled by different interface elements with appropriate interface
stiffness. Besides, the motorized built-in spindle model was created and implemented in the whole
machine model. As a dynamic evaluation of the machine tool, the vibration modes, dynamic stiffness,
and machining stability of the spindle tool system were predicted. The results were used to compare
the influence of the use of linear roller guides with different preload.

2. Construction of Milling Machine

In this study, a horizontal milling machine was designed, as shown in Figure 1, in which the
table was mounted on the machine base and was driven through the X-axis linear feeding mechanism.
The vertical column was mounted on the machine base through the Z-axis feeding mechanism.
The spindle ram was mounted on the vertical column, which can move along vertical direction through
the Y-axis feeding mechanism. To enhance the rigidity of the feeding mechanism, the guideway
systems were assembled by linear roller guides and sliding guides, in which the sliding guides
were grounded, hardened, and then coated with scrapped Turcite-B liners. The use of the Turcite-B
slideways can also increase the damping property of the machining system [23]. All the structural
components were fabricated from gray iron. In each feeding mechanism, the driven ball screw
(Hiwin-R32-10K4-FSC) has a diameter of 32 mm, a lead pitch of 10 mm, and a basic dynamic load
rating C of 2.52 kN [24]. The screw shaft was slightly preloaded to a level of 0.05C so as to lessen
the axial backlash. Moreover, two standardized ball-screw support units coded EK15 were used at
both ends of the screw shaft to ensure its rigidity. Each feeding system was also equipped with linear
roller guide modules (INA-RUS19069), which can be preloaded to different amounts by means of the
adjusting the gib in spaces, normally between 10% and 20% of the basic dynamic loading capacity [25].
In addition, a motorized spindle unit was installed on the feeding ram of the spindle.
Appl. Sci. 2016, 6, 76 3 of 12
Appl. Sci. 2016, 6, 76    3 of 13 

Figure 1. Schematics of a horizontal milling machine with moving column and hybrid   guideways.
(a) Main structure modules of the milling machine, (b) Y-axis guideway system, (c) X
Figure 1. Schematics of a horizontal milling machine with moving column and hybrid guideways. (a)  and Z-axis
guideway system.
Main  structure  modules  of  the  milling  machine,  (b)  Y‐axis  guideway  system,  (c)  X  and  Z‐axis 
guideway system. 
The key factor for accurate construction of the analysis model of a machine tool structure is the
The key factor for accurate construction of the analysis model of a machine tool structure is the 
modeling of the feeding mechanism, which usually consists of various linear components of rolling
modeling of the feeding mechanism, which usually consists of various linear components of rolling 
motion type.
motion  These
type.  interfaces
These  interfaces mostly
mostly  affect thestructure 
affect  the  structurecharacteristics 
characteristics in loading
in  loading  and  and damping
damping 
capacities. Hence
capacities.  the the 
Hence  modeling of of 
modeling  thethe 
interface greatly
interface  greatly determines
determines whether the simulation 
whether  the  simulationresults 
results can
approach the real characteristics of the system. A method for the simulation of the rolling
can approach the real characteristics of the system. A method for the simulation of the rolling and  and sliding
interfaces is presented in next section as follows.
sliding interfaces is presented in next section as follows. 

3. Modeling of the Milling Machine

3. Modeling of the Milling Machine 

3.1. Modeling of the Joint/Interface  

3.1. Modeling of the Joint/Interface 

3.1.1.3.1.1. Rolling Interface 
Rolling Interface
According to Hertzian theory, the contact force between a rolling element and the raceways can 
According to Hertzian theory, the contact force between a rolling element and the raceways can
be related to the local deformation at the contact point as the expression (Figure 2): 
be related to the local deformation at the contact point as the expression (Figure 2):
Q  K h δ 3/2   (1) 
Q “ Kh δ3{2 (1)
where Q denotes the contact force and  is the elastic deformation at the contact point. Kh represents 
the Hertz constant, which is determined by the contact geometry of the ball groove or raceway and 
where Q denotes the contact force and δ is the elastic deformation at the contact point. Kh represents
the material properties of the contacting components. Details are available in the literatures [26,27]. 
the Hertz constant, which is determined by the contact geometry of the ball groove or raceway and
The contact stiffness at the contact point can further be determined from Equation 2. 
the material properties of the contacting components. Details are available in the literatures [26,27].
dQ 3 3 2/3 1/3 from Equation (2).
K n  canfurther
The contact stiffness at the contact point K h δ1/be
2
determined
Kh Q   (2) 
dδ 2 2
dQ 3 3 2{3
Kn “ “ Kh δ1{2 “ Kh Q1{3
For a roller guide, the relationship between the contact force Q and the local deformation  at  (2)
dδ 2 2
the contact point of the roller to the flat raceway can be described as   
For a roller guide, the relationship between πL2 Eeq force Q and the local deformation δ at the
2Q the contact
δ  ln(
contact point of the roller to the flat raceway can be described )   as (3) 
πLEeq Q
2Q πL2 Eeq
δ“ lnp q
πLEeq Q
(3)

Eeq “ 2{pp1 ´ µ2a q{Ea ` p1 ´ µ2b q{Eb q

Appl. Sci. 2016, 6, 76
Appl. Sci. 2016, 6, 76    44 of 13
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E eq  2 / ((1  μ 2a ) / E a  (1  μ b2 ) / E b )
In above equation, Eeq is the relative elastic stiffness between the contacting bodies. L is the length
In  above  equation,  E eq   is  the  relative  elastic  stiffness  between  the  contacting  bodies.  L  is  the 
of the roller. The normal stiffness is thus given as
length of the roller. The normal stiffness is thus given as 
«
  ff
2
2 πL 2Eeq 2 ´11
K A “  2 lnp πL Eeqq ´ 2  (4)
K A   πLEeq ln( Q ) πLEeq    (4) 
 πLEeq Q πLEeq 

 
Figure 2. Modeling of the rolling and sliding interfaces. (a) Schematic of angular contact bearing,
Figure 2. Modeling of the rolling and sliding interfaces. (a) Schematic of angular contact bearing, (b) 
(b) Modeling of the contact interface between rolling ball and groove, (c) Schematic of sliding guideway
Modeling of the contact interface between rolling ball and groove, (c) Schematic of sliding guideway 
and the modeling of the antifriction sliding interface.  
and the modeling of the antifriction sliding interface. 

To reduce the complexity in model creation and mesh generation of the motion components, 
To reduce the complexity in model creation and mesh generation of the motion components, such
such as the ball bearings in the spindle unit, the contact configuration between rolling ball and the 
as the ball bearings in the spindle unit, the contact configuration between rolling ball and the raceway
raceway is modeled as a two‐point contact mode. The outer and inner 
is modeled as a two-point contact mode. The outer and inner raceways were raceways were respectively 
respectively simplified
simplified as a part of the spindle shaft and housing in geometry. The outer and inner raceways are 
as a part of the spindle shaft and housing in geometry. The outer and inner raceways are directly
directly connected using a series of spring elements by neglecting the rolling elements, as shown in 
connected using a series of spring elements by neglecting the rolling elements, as shown in Figure 2.
Figure 2. 
3.1.2. Sliding Interface
3.1.2. Sliding Interface 
The contact properties of the elastic interface layer such as Turcite-B in the sliding guide system
can be modeled by the following exponential relationship [11].
The contact properties of the elastic interface layer such as Turcite‐B in the sliding guide system 
can be modeled by the following exponential relationship [11]. 
δn “ Cn Pnmm (5)
δ n  C n Pn   (5) 
2 ), C is coefficient of normal
where
Where δnn isnormal
isnormal deformation (mm), PPnn isis normal
deformation (mm), normal pressure
pressure (N/mm
(N/mm2),  Cnn  is  coefficient  of  normal 
contact flexibility, and m is coefficient of non-linearity of deformations. The contact stiffness in the
contact flexibility, and m is coefficient of non‐linearity of deformations. The contact stiffness in the 
normal direction can be obtained
normal direction can be obtained as as
dPn 1
KKn “ d Pn “ 1 pp1n´
1 m
m   (6)
(6) 
dδnn Cnnm
dδ C
n n
m
For modeling sliding guides in a finite element model, the spring layer model was employed to
For modeling sliding guides in a finite element model, the spring layer model was employed to 
simulate the contact characteristics of the antifriction liners between the guide rail and sliding block.
simulate the contact characteristics of the antifriction liners between the guide rail and sliding block. 
The antifriction layer was replaced by interface elements distributed over this interface (Figure 2),
The antifriction layer was replaced by interface elements distributed over this interface (Figure 2), 
which was described by the stiffness matrix,
which was described by the stiffness matrix, 

  rNs
N T rTs
T T rDs
 D  TdA
dA  
ż
T T
K ee s] “
[ rK rNsN rTs (7) 
(7)
A
A
Appl. Sci. 2016, 6, 76 
Appl. Sci. 2016, 6, 76   of 12  
55 of 13

where [N] and [T] is the interpolation function and coordinate transformation matrix, respectively, 
and [D] is the contact stiffness matrix of the interface layer described as [D] = diag[Kn, Ks]. Kn and Ks is 
where [N] and [T] is the interpolation function and coordinate transformation matrix, respectively, and
the contact stiffness in normal and tangential directions of the contact interface.   
[D] is the contact stiffness matrix of the interface layer described as [D] = diag[Kn , Ks ]. Kn and Ks is the
contact stiffness in normal and tangential directions of the contact interface.
3.2. Modeling of Spindle Unit   
3.2. Modeling
Figure  3 ofshows 
Spindle Unit
the  motorized  spindle  installed  in  the  milling  machine,  in  which  the  spindle 
shaft Figure
is  supported  in  housing 
3 shows the motorizedby  two  pairs 
spindle of  bearings 
installed 7009C 
in the milling at  front 
machine, and  rear 
in which ends  in shaft
the spindle DT 
arrangement, respectively, which were preloaded at medium amount of 290 N with an axial rigidity 
is supported in housing by two pairs of bearings 7009C at front and rear ends in DT arrangement,
of 66 N/μm. In addition, a cutter with the diameter of 20 mm and length of 60 mm was clamped on 
respectively, which were preloaded at medium amount of 290 N with an axial rigidity of 66 N/µm.
the spindle tool holder (BT30). To investigate the dynamic behavior of the spindle, a solid model of 
In addition, a cutter with the diameter of 20 mm and length of 60 mm was clamped on the spindle tool
the spindle bearing system including the rotating shaft and the spindle housing was prepared and 
holder (BT30). To investigate the dynamic behavior of the spindle, a solid model of the spindle bearing
meshed  with  tetrahedral 
system including element 
the rotating (see the
shaft and Figure  3). housing
spindle The  built 
was in prepared
motor  was 
andsimplified 
meshed with as tetrahedral
a  cylinder 
having  equivalent  weight  as  the  original  unit.  Regarding  the  supporting  bearings, 
element (see Figure 3). The built in motor was simplified as a cylinder having equivalent weight the  outer asand 
the
inner rings were respectively simplified as a part of the spindle shaft and housing in geometry. A 
original unit. Regarding the supporting bearings, the outer and inner rings were respectively simplified
series of spring elements were employed to directly connect the inner and outer rings, modeling the 
as a part of the spindle shaft and housing in geometry. A series of spring elements were employed
contact state between rolling ball and groove. For finite element analysis, all the metal components 
to directly connect the inner and outer rings, modeling the contact state between rolling ball and
have the following material properties of carbon steel: elastic modulus E = 200 GPa, Poisson′s ratio 
groove. For finite element analysis, all the metal components have the following material properties  
= 0.3, and density   = 7800 Kg/m
of carbon steel: elastic modulus . The overall contact stiffness of each bearing was calculated as 340 
3
E = 200 GPa, Poisson1 s ratio µ = 0.3, and density ρ = 7800 Kg/m3 .
N/μm.  The  stiffness  of  each  bearing 
The overall contact stiffness of each bearing is  was
distributed 
calculated on 
as the  spring  The
340 N/µm. elements  circumferentially 
stiffness of each bearing
surrounding the spindle shaft created in the model. The tool 
is distributed on the spring elements circumferentially surrounding holder the
with  cutter was modeled as a 
spindle shaft created in the
solid cylinder and assumed to be firmly connected with the spindle nose, which was considered as a 
model. The tool holder with cutter was modeled as a solid cylinder and assumed to be firmly connected
part of the spindle shaft. 
with the spindle nose, which was considered as a part of the spindle shaft.

 
Figure 3. Solid model and finite element model of spindle unit.
Figure 3. Solid model and finite element model of spindle unit. 

3.3. Finite Element Model of Milling Machine 
3.3. Finite Element Model of Milling Machine
Figure 
Figure 44 presents
presents 
thethe  finite 
finite element 
element modelmodel 
of millingof  machinestructure.
milling  machinestructure.  Each component
Each structural structural 
component 
of the system of was
the  meshed
system was 
withmeshed with  ten‐node elements,
ten-node tetrahedral tetrahedral elements, 
with a total ofwith  a  total 
124,648 of  124,648 
elements and
elements  and  224,175 
224,175 nodes. nodes.  The 
The components components 
of the of  the  feeding 
feeding mechanism, mechanism, 
such as such linear
ball screw/nut, as  ball  screw/nut, 
roller guides,
linear roller guides, and sliding guideways were included in the machine model. For linear roller 
and sliding guideways were included in the machine model. For linear roller guides, the overall
guides, the overall structural stiffness K
structural stiffness Kn in normal direction n in normal direction was 500 and 850 N/μm for normal and 
was 500 and 850 N/µm for normal and medium preloaded
medium preloaded roller guides. Regarding to the sliding guideway with Turcite‐B antifriction layer, 
roller guides. Regarding to the sliding guideway with Turcite-B antifriction layer, the contact stiffness
the 
wascontact 
measured stiffness 
as 750was 
kN/µm measured 
per unitas area
750  kN/μm 
in meterper  unit 
[23]. Thearea  in  meter 
overall [23]. 
contact The  overall 
stiffness at ball contact 
groove
stiffness at ball groove was estimated as 1.62 kN/μm according to the specifications of the ball screw 
was estimated as 1.62 kN/µm according to the specifications of the ball screw [24]. In order to obtain a
[24]. 
wholeIn  order  to 
analysis obtain 
model of aa milling
whole machine,
analysis  model  of  a  milling system
the spindle-bearing machine,  the  spindle‐bearing 
created in the above section system 
was
created  in  the inabove 
incorporated section 
the spindle was asincorporated 
ram, shown in Figure in  the 
4. spindle 
Also, in ram, 
finiteas  shown analysis,
element in  Figure  the4. materials
Also,  in 
finite element analysis, the materials used for structural components are made of gray cast iron with 
used for structural components are made of gray cast iron with an elastic modulus E = 660 GPa,
Poisson1 s ratio µ = 0.3, and density ρ = 7200 Kg/m
an elastic modulus E = 660 GPa, Poisson′s ratio   = 0.3, and density 
3 . The materials of  = 7200 Kg/m . The materials of 
linear rolling3components have
1
linear rolling components have an elastic modulus E = 210 GPa, Poisson′s ratio 
an elastic modulus E = 210 GPa, Poisson s ratio µ = 0.3, and density ρ = 7800 Kg/m  = 0.3, and density 
3 .The vibration  
= 7800 Kg/m
mode shapes.The vibration mode shapes associated with the frequencies of the milling system were 
3 associated with the frequencies of the milling system were obtained by implementing
obtained by implementing the modal analysis into the finite element computation. 
the modal analysis into the finite element computation.  
Appl. Sci. 2016, 6, 76 6 of 12

Appl. Sci. 2016, 6, 76    6 of 13 

Appl. Sci. 2016, 6, 76    6 of 13 

 
Figure 4. Finite element models of the milling machine. 
Figure 4. Finite element models of the milling machine.
 
The  harmonic  analysis  was  performed  to  measure  the  frequency  response  at  the  end  of  the 
Figure 4. Finite element models of the milling machine. 
The harmonic analysis was performed to measure the frequency response at the end of the cuter.
cuter.  In  the  finite  element  governing  equation  for  harmonic  analysis,  the  damping  matrix  was 
In the finite
The element
harmonic governing equation
analysis  was  for harmonic
performed  analysis,
to  measure  the damping
the  frequency  response matrix
at  the was
assumed to be proportional to the structural stiffness matrix [K] according to the relationship [C] =  end assumed
of  the  to
be 
proportional tofinite 
cuter.  In  the 
[K]. The value β the structural stiffness matrix
element  governing  [K]for 
equation  according
harmonic toanalysis, 
the relationship [C] = matrix 
the  damping  β[K]. The
mr, representing the structural damping factor, is calculated from 2 mr/wr, where mr 
was value
, assumed to be proportional to the structural stiffness matrix [K] according to the relationship [C] = 
representing the structural damping factor, is calculated from 2 ξmr /wr , where ξmr is the modal
βmris the modal damping ratio for spindle dominant vibration mode, about 2.5%. 
[K]. The value β
damping mr, representing the structural damping factor, is calculated from 2 mr/wr, where mr 
ratio for spindle dominant vibration mode, about 2.5%.
is the modal damping ratio for spindle dominant vibration mode, about 2.5%. 
4. Results and Discussions 
4. Results and Discussions
4. Results and Discussions 
4.1. Frequency Response Function of Spindle Unit 
4.1. Frequency Response Function of Spindle Unit
4.1. Frequency Response Function of Spindle Unit 
Figure  5  shows  the  main  vibration  modes  of  the  spindle  unit  and  the  first  four  modal 
Figure 5 shows the main vibration modes of the spindle unit and the first four modal frequencies
frequencies are 1046, 1567, 2972, and 3855 Hz respectively. The harmonic analysis was performed to 
Figure  5  shows  the  main  vibration  modes  of  the  spindle  unit  and  the  first  four  modal 
areassess the frequency response of spindle under unit force at the tool tip. For validation of the finite 
1046, 1567, 2972, and 3855 Hz respectively. The harmonic analysis was performed to assess the
frequencies are 1046, 1567, 2972, and 3855 Hz respectively. The harmonic analysis was performed to 
frequency response of spindle under unit force at the tool tip. For validation of the finite element
element model, the dynamic characteristic of the spindle was measured by conducting the vibration 
assess the frequency response of spindle under unit force at the tool tip. For validation of the finite 
model,
test  the
on  dynamic
the  spindle characteristic of the
unit.  A  cutter  spindle
with  was measured
the  diameter  by conducting
of  20  mm  and  length  the vibration
of  60 
element model, the dynamic characteristic of the spindle was measured by conducting the vibration mm  was test on the
firmly 
spindle
test  on  the  spindle  unit.  A  cutter  with  the  diameter  of  20  mm  and  length  of  60  mm  was  firmly  the
unit. A cutter with the diameter of 20 mm and length
clamped on the spindle tool holder, with an overhang length of 30 mm.  of 60 mm was firmly clamped on
spindle tool holder, with an overhang length of 30 mm.
clamped on the spindle tool holder, with an overhang length of 30 mm. 

   
Figure 5. Fundamental modal shapes of spindle. 
Figure 5. Fundamental modal shapes of spindle. 
Figure 5. Fundamental modal shapes of spindle.

In testing, the accelerometer was mounted on the cutter to measure the vibration signal excited 
In testing, the accelerometer was mounted on the cutter to measure the vibration signal excited 
In testing, thehammer 
accelerometer wasThe mounted on the cutter to measure the vibration signal excited
by by  the 
the  impact 
impact  hammer  at at tool 
tool tip. 
tip.  The  frequency 
frequency response 
response function 
function was 
was then  extracted 
then  from 
extracted  the 
from  the 
by recorded FFT spectrum. As shown in Figure 6, the spindle shaft vibrates greatly at a frequency of 
the
recorded FFT spectrum. As shown in Figure 6, the spindle shaft vibrates greatly at a frequency of  the
impact hammer at tool tip. The frequency response function was then extracted from
recorded FFT spectrum. As shown in Figure 6, the spindle shaft vibrates greatly at a frequency of
Appl. Sci. 2016, 6, 76 7 of 12

Appl. Sci. 2016, 6, 76    7 of 13 
1043 Hz, but has less vibration at 1454 Hz. The spindle unit was found to become more compliant
1043 Hz, but has less vibration at 1454 Hz. The spindle unit was found to become more compliant 
when the first bending mode was excited. The maximum compliance predicted by finite element model
when  the  first  bending  mode  was  excited.  The  maximum  compliance  predicted  by  finite  element 
7 of 13 
and measured from physical unit is 0.85 µm/N at  1048 Hz and 0.73 µm/N at 1046 Hz, respectively.
Appl. Sci. 2016, 6, 76 
model  and  measured  from  physical  unit  is  0.85  μm/N  at  1048  Hz  and  0.73  μm/N  at  1046  Hz, 
1043 Hz, but has less vibration at 1454 Hz. The spindle unit was found to become more compliant 
It is obvious that the spindle model has a dynamic behavior comparable to that measured in the
respectively.  It  is  obvious  that  the  spindle  model  has  a  dynamic  behavior  comparable  to  that 
when 
physical the  first  bending  mode  was  excited.  The  maximum  compliance  predicted  by  finite  element 
spindle.
measured in the physical spindle.   
model  and  measured  from  physical  unit  is  0.85  μm/N  at  1048  Hz  and  0.73  μm/N  at  1046  Hz, 
respectively. Frequency
It  is  obvious  that at tool
response function the endspindle  model  has  a  dynamic  behavior 
Frequency comparable 
response function at tool end to  that 
1.0 1.0
measured in the physical spindle. 
0.9
  0.8 PRedicted FRF Predicted FRF
FRF, Amplitude, (um/N)

0.8 Measured FRF

0.6
Measured FRF
0.7 0.4 Frequency response function at tool end

FRF, Real (um/N)

Frequency response function at tool end
0.6
1.0 0.2
1.0
0.5
0.9 0.0
0.8
PRedicted FRF Predicted FRF
FRF, Amplitude, (um/N)

0.4
0.8 -0.2
0.6
Measured FRF Measured FRF
0.3
0.7 -0.4
0.4

FRF, Real (um/N)

0.2
0.6 -0.6
0.2
0.1
0.5 -0.8
0.0
0.0
0.4 -1.0
-0.2
0.3 0 500 1000 1500 2000 2500 3000 3500 4000 -0.4 0 500 1000 1500 2000 2500 3000 3500 4000
0.2 Frequency, (Hz) -0.6 Frequency, (Hz)
0.1 -0.8
0.0 (a)  -1.0 (b)
0 500 1000 1500 2000 2500 3000 3500 4000 0 500 1000 1500 2000 2500 3000 3500 4000
Frequency,of 
Figure  6.  Comparisons  (Hz)
the  frequency  response  functions  measured Frequency,
from  the  spindle  unit  and 
(Hz)
Figure 6. Comparisons of the frequency response functions measured from the spindle unit and
predicted by the spindle model. (a) Amplitude of the FRFs, (b) Real part of the FRFs. 
predicted by the spindle(a) 
model. (a) Amplitude of the FRFs, (b) Real part of (b)the FRFs.
Figure  6.  Comparisons  of  the  frequency  response  functions  measured  from  the  spindle  unit  and 
4.2. Natural Vibration Modes of Milling Machine 
predicted by the spindle model. (a) Amplitude of the FRFs, (b) Real part of the FRFs. 
4.2. Natural Vibration Modes of Milling Machine
Results of modal analysis indicate that the fundamental modes are associated with the vibration 
of  the  spindle 
Results of modal ram  and  vertical 
analysis column 
indicate that structure, 
4.2. Natural Vibration Modes of Milling Machine  as  illustrated 
the fundamental modes in  are
Figure  7.  The  first 
associated with mode  is  the 
the vibration
rolling 
of the spindle motion  of  vertical  column  of  the  Z  axis  at  34  Hz,  which  is  dominated 
ram and vertical column structure, as illustrated in Figure 7. The first mode is the rolling by  the  feeding 
Results of modal analysis indicate that the fundamental modes are associated with the vibration 
motion mechanism of Z axis. The second mode is the twisting vibration of the vertical column and spindle 
the Zcolumn 
of  the  spindle  column
of vertical ram  and of vertical  axis at structure, 
34 Hz, which is dominated
as  illustrated  by 7. 
in  Figure  the feeding
The  mechanism
first  mode  is  the  of
ram  about  Y‐axis  at  63  Hz.  The  third  and  fourth  modes  at  98  and  119  Hz  are  yawing  (twisting) 
Z axis. The second mode is the twisting vibration of the vertical column and spindle ram
rolling  motion  of  vertical  column  of  the  Z  axis  at  34  Hz,  which  is  dominated  by  the  feeding  about Y-axis
vibration  of  spindle  ram  about  the  Z‐axis.  It  is  noticed  that  in  the  second  and  fourth  modes  the 
at 63 mechanism of Z axis. The second mode is the twisting vibration of the vertical column and spindle 
Hz. The third and fourth modes at 98 and 119 Hz are yawing (twisting) vibration of spindle ram
spindle nose shows a greater displacement, which can affect the machining ability of the machine. In 
aboutram  Z-axis.
theabout  It is at 
Y‐axis  noticed
63  Hz. that
The in the and 
third  second
fourth andmodes 
fourthat modes
98  and the
119 spindle nose shows
Hz  are  yawing 
addition,  these  modes are  affected  by  the  feeding  mechanisms  of  the  vertical column  and spindle 
a greater
(twisting) 
vibration  of 
displacement, spindle  ram  about  the  Z‐axis.  It  ability
is  noticed  that machine.
in  the  second  and  fourth  modes  the 
ram. The other high frequency modes are associated with the bending vibration of the spindle shaft.  are
which can affect the machining of the In addition, these modes
spindle nose shows a greater displacement, which can affect the machining ability of the machine. In 
affected by the feeding mechanisms of the vertical column and spindle ram. The other high frequency
addition,  these  modes are  affected  by  the  feeding  mechanisms  of  the  vertical column  and spindle 
modes are associated with the bending vibration of the spindle shaft.
ram. The other high frequency modes are associated with the bending vibration of the spindle shaft. 

 
Figure 7. Fundamental vibration modes of the milling machine. 
 
Figure 7. Fundamental vibration modes of the milling machine.
Figure 7. Fundamental vibration modes of the milling machine. 
Appl. Sci. 2016, 6, 76 8 of 12

4.3. Frequency Response Functions of the Milling Machine

Appl. Sci. 2016, 6, 76    8 of 13 

4.3. Frequency Response Functions of the Milling Machine 
Figure 8 illustrates the predicted frequency response at the tool end of the milling machine in
Figure 8 illustrates the predicted frequency response at the tool end of the milling machine in X 
X and Y directions, respectively, which are expressed in terms of dynamic compliance in magnitude as a
and Y directions, respectively, which are expressed in terms of dynamic compliance in magnitude as 
function of the frequency. As observed in the figure, the spindle of the milling machine behaves similar
a function of the frequency. As observed in the figure, the spindle 
behaviors in X and Y axis, especially, at the higher frequency mode of  above
the  milling 
1000machine 
Hz. Thebehaves 
maximum
similar  behaviors  in  X  and  Y  axis,  especially,  at  the  higher  frequency  mode  above  1000  Hz.  The 
dynamic compliance occurs at the frequency of 1290 Hz, which is higher than the measured natural
maximum  dynamic  compliance  occurs  at  the  frequency  of  1290  Hz,  which  is  higher  than  the 
frequency of the spindle unit. This is because of the constrained of the spindle housing on the spindle
measured  natural  frequency  of  the  spindle  unit.  This  is  because  of  the  constrained  of  the  spindle 
ram. The maximum compliance in X and Y direction is 1.42 µm/N (1285 Hz) and 1.49
housing on the spindle ram. The maximum compliance in X and Y direction is 1.42  µm/N (1290 Hz).
m/N (1285 Hz) 
The mode inducing the peak vibration of the cutter is mainly associated with the bending
and 1.49  m/N (1290 Hz). The mode inducing the peak vibration of the  cutter  is mainly associated  vibration of
the spindle shaft.
with  the  The other
bending  apparent
vibration  of  the  modes
spindle occurring
shaft.  The at lower
other  frequency
apparent  below
modes  200 Hz
occurring  at are mainly
lower 
caused by the vibration of the spindle ram and movable column.
frequency below 200 Hz are mainly caused by the vibration of the spindle ram and movable column. 

Frequency reponse functions at tool end Frequency reponse functions at tool end
1.60 1.00
1.40 0.80
FRFs, Amplitude [um/N]

FRFs, Real part [um/N]

1.20 0.60
0.40
1.00
FRF in X-axis 0.20
0.80
FRF in Y-axis 0.00
0.60
-0.20
0.40 FRF in X-axis
-0.40
FRF in Y-axis
0.20 -0.60
0.00 -0.80
0 200 400 600 800 1000 1200 1400 1600 1800 2000 0 200 400 600 800 1000 1200 1400 1600 1800 2000
Frequency, (Hz) Frequency, (Hz)

(a)  (b)
Figure 8. Comparisons of the predicted frequency response functions at tool end of milling machine 
Figure 8. Comparisons of the predicted frequency response functions at tool end of milling machine
modelin X and Y directions. (a) Amplitude of the FRFs, (b) Real part of the FRFs. 
modelin X and Y directions. (a) Amplitude of the FRFs, (b) Real part of the FRFs.
4.4. Machining Stability   
4.4. Machining Stability
To  get  insight  into  the  machining  performance  of  the  milling  machine  at  design  stage,  the 
To get insight
machining  into was 
stability  the assessed 
machining performance
based  on  frequency of the milling
response  machine
functions  at design
of  the  stage,
tool  tip.  The  the
machining stability was assessed based on frequency response functions
machining stability of the milling machine was predicted using  of the tool tip. The machining
the analytical model developed in 
study 
stability of [28].  In  their machine
the milling approach, was
the  predicted
time‐varying  force 
using coefficient 
the analytical of  model
the  dynamic  milling 
developed inprocess 
study [28].
model  was  approximated  by  Fourier‐series  components.  The  stability 
In their approach, the time-varying force coefficient of the dynamic milling process model relationship  between  the  was
chatter‐free axial cutting depths (Z
approximated min) and the spindle speed (n) in end‐mill operation as follows. 
by Fourier-series components. The stability relationship between the chatter-free axial
The speed‐dependent transfer function H(jw) representing the ratio of the Fourier transform of 
cutting depths (Zmin ) and the spindle speed (n) in end-mill operation as follows.
the displacement at the tool tip over the dynamic cutting force can be expressed as H(jw) = Re(w) + 
The speed-dependent transfer function H(jw) representing the ratio of the Fourier transform of the
jIm(w), where Re and Im are, respectively, the real and imaginary parts of the transfer function of the 
displacement at the tool tip over the dynamic
spindle tool tip. The limit cutting depth Z cutting force can be expressed as H(jw) = Re (w) + jIm (w),
min for stable machining at spindle speed n is defined as 
where Re and Im are, respectively, the real and imaginary parts of the transfer function of the spindle
2πRe I
tool tip. The limit cutting depth Zmin forZstable  machining
(1  mat)2spindle
  speed n is defined as (8) 
min
NKt Re
´2πRe Im 2
Zmin
60ω “ p1 ` q (8)
n c
, NKt Re
N (2kπ   )   (9) 
60ω1c
n“π Np2kπ
2 tan `( Iφq
m / Re)
, k  lobes(0,1, 2...) (9)
“ π ´ 2tan ´1 pI {R q k “ lobesp0, 1, 2...q
In the above equation, Kt  is the cutting resistance coefficients in the tangential direction to the 
φ m e
cutter,  N  is  the  number  of  cutter  teeth,  and  k  is  the  lobe  number.  The  machining  stability  was 
In the above equation, Kt is the cutting resistance coefficients in the tangential direction to the
calculated based on the vibration modes that cause the tool to deform greatly. Therefore, according 
cutter, N is the number of cutter teeth, and k is the lobe number. The machining stability was calculated
to  the  tool  end  FRFs,  the  apparent  peak  vibrations at  lower and  high frequency  were selected  for 
basedprediction of the machining stability. The analysis of machining stability was used to evaluate how 
on the vibration modes that cause the tool to deform greatly. Therefore, according to the tool
end FRFs, the apparent
the  linear  peak vibrations
guide  preload  will  affect at lower
the  and high
dynamic  frequency
behavior  were selected
and  machining.  for prediction
Considering  of the
that  the 
machining stability. The analysis of machining stability was used to evaluate how the linear guide
yawing and twisting modes cause the tool to deform greatly and the two modes occur aligning in X 
preload will affect the dynamic behavior and machining. Considering that the yawing and twisting
and Y directions, therefore, the machining stability in X and Y directions are calculated, respectively. 
modes cause the tool to deform greatly and the two modes occur aligning in X and Y directions,
therefore, the machining stability in X and Y directions are calculated, respectively. In this way, the
Appl. Sci. 2016, 6, 76 9 of 12

Appl. Sci. 2016, 6, 76    9 of 13 
coupled effect of the dominant vibration modes was ignored when calculating the stability lobe curves.
In this way, the coupled effect of the dominant vibration modes was ignored when calculating the 
A two-tooth carbide cutter was employed to machine
Appl. Sci. 2016, 6, 76    the stock material of Al7075 alloys and9 of 13 titanium
 
stability  lobe  curves.  A  two‐tooth  carbide  cutter  was  employed  to  machine  the  stock  material  of 
alloysIn this way, the coupled effect of the dominant vibration modes was ignored when calculating the 
Ti-6Al-4V alloys
Al7075 alloys  at high alloys 
and  titanium  and low speed machining.
Ti‐6Al‐4V alloys at  The low 
high and  cutting resistance
speed  machining. coefficients
The cutting were
calibrated as K = 796 N/mm 2 of for Al7075 alloys and K = 2000 N/mm2 for Ti6Al4V alloys [28,29].
stability  lobe 
t curves.  A  two‐tooth  carbide  cutter  was  employed 
t to  machine  the 
resistance coefficients were calibrated as Kt = 796 N/mm  of for Al7075 alloys and Kt = 2000 N/mm2 
2 stock  material  of 
Al7075 alloys 
Figure and  titanium 
9 presents alloys 
the stability
for Ti6Al4V alloys [28,29].  Ti‐6Al‐4V alloys at 
lobes in the X and Yhigh and directionslow  speed  machining. 
predicted The cutting 
at the vibration mode of
resistance coefficients were calibrated as K
machine tool  = 796 N/mm 2 of for Al7075 alloys and Kt = 2000 N/mm2 
structure, respectively. The limited depth is 4.2 mm in the X-direction and 10.1 mm in the
Figure 9 presents the stability lobes in the X and Y directions predicted at the vibration mode of 
t

for Ti6Al4V alloys [28,29]. 
machine tool structure, respectively. The limited depth is 4.2 mm in the X‐direction and 10.1 mm in 
Y-direction, respectively. Comparison of the results of stability analysis indicates that the machine tool
the  Figure 9 presents the stability lobes in the X and Y directions predicted at the vibration mode of 
Y‐direction, 
has a different limitedrespectively.  Comparison 
depth for stable machining of  the in results 
X and of  stability  analysis 
Y directions when the indicates 
cutter that  the 
is operated
machine tool structure, respectively. The limited depth is 4.2 mm in the X‐direction and 10.1 mm in 
machine  tool  has  a  different  limited  depth  for  stable  machining  in  X  and  Y  directions  when  the 
under lower speed. As found from the predicted tool end FRFs of milling machine, the results of
the  Y‐direction,  respectively.  Comparison  of  the  results  of  stability  analysis  indicates  that  the 
cutter is operated under lower speed. As found from the predicted tool end FRFs of milling machine, 
stability analysis
machine  alsoa indicate
tool  has  different that thedepth 
limited  dynamic characteristic
for  stable  machining  ofin the milling
X  and  machinewhen 
Y  directions  is greater
the  in
the results of stability analysis also indicate that the dynamic characteristic of the milling machine is 
the Ycutter is operated under lower speed. As found from the predicted tool end FRFs of milling machine, 
direction than in the X direction, which further bring the higher limited depth in Y direction
greater in the Y direction than in the X direction, which further bring the higher limited depth in Y 
compared with the X direction. This result gives a suggestion for the improvement of the structure of
the results of stability analysis also indicate that the dynamic characteristic of the milling machine is 
direction compared with the X direction. This result gives a suggestion for the improvement of the 
the milling machine.
greater in the Y direction than in the X direction, which further bring the higher limited depth in Y 
structure of the milling machine.   
direction compared with the X direction. This result gives a suggestion for the improvement of the 
Stability lobes diagram in X-direction Stability lobes diagram in Y-direction
structure of the milling machine.    16
10
9
Stability lobes diagram in X-direction Stability lobes diagram in Y-direction
Cutting depth, (mm)

10 8 Cutting depth, (mm) 1614

97
Cutting depth, (mm)

86 1412
Cutting depth, (mm)

75
64 1210
53
42 10 8
400 500 600 700 800 900 1000 1100 1200 400 500 600 700 800 900 1000 1100 1200
3
Spindle speed, (rpm) Spindle speed, (rpm)
2 8
400 500 600 700 (a) 
800 900 1000 1100 1200 400 500 600 700 (b)800 900 1000 1100 1200
Spindle speed, (rpm) Spindle speed, (rpm)
Figure 9. Predicted stability lobe diagrams in X and Y directions based on the vibration mode associated 
(a)  lobe diagrams in X and Y directions based on the(b)
Figure 9. Predicted stability vibration mode associated
with the machine tool structure. (a) Stability lobes in X direction, (b) Stability lobes in Y direction. 
the machine tool structure. (a) Stability lobes in X direction, (b) Stability lobes in Y direction.
with Figure 9. Predicted stability lobe diagrams in X and Y directions based on the vibration mode associated 
with the machine tool structure. (a) Stability lobes in X direction, (b) Stability lobes in Y direction. 
On  the  other  hand,  the  predicted  stability  lobes  diagrams  based  of  the  vibration  mode  of 
spindle structure are illustrated in Figure 10. As can be seen, the limited depth for high speed stable 
On the other hand, the predicted stability lobes diagrams based of the vibration mode of spindle
structure On  the  other 
machining in X 
are illustrated hand,  the  predicted  stability  lobes  diagrams  based  of  the  vibration  mode  of 
direction is about 6.02 mm, almost equal to that in Y direction. This is an expected 
in Figure 10. As can be seen, the limited depth for high speed stable machining
spindle structure are illustrated in Figure 10. As can be seen, the limited depth for high speed stable 
phenomenon  since  this mm, stability  is  calculated  based  on direction.
the  vibration 
in X direction is about 6.02 almost equal to that in Y Thismode  associated phenomenon
is an expected with  the 
machining in X  direction is about 6.02 mm, almost equal to that in Y direction. This is an expected 
bending motion of the spindle shaft. 
sincephenomenon 
this stability since 
is calculated based on the vibration mode associated with the bending motion of the
this  stability  is  calculated  based  on  the  vibration  mode  associated  with  the 
spindle shaft. Stability lobes diagram in X-direction- spindle mode
bending motion of the spindle shaft.  Stability lobes diagram in Y-direction spindle mode
10 10
Stability lobes diagram in X-direction- spindle mode Stability lobes diagram in Y-direction spindle mode
C u ttin g d e p th , (m m )
C utting de pth, (m m )

10 10
8 8
C u ttin g d e p th , (m m )
C utting de pth, (m m )

8 8
6 6

6 6
4 4
4000 4500 5000 5500 6000 6500 7000 7500 8000 4000 4500 5000 5500 6000 6500 7000 7500 8000

4 Spindle speed, (rpm) 4 Spindle speed, (rpm)

4000 4500 5000 5500 (a) 
6000 6500 7000 7500 8000 4000 4500 5000 5500 6000
(b) 6500 7000 7500 8000

Spindle speed, (rpm) Spindle speed, (rpm)

Figure 10. Predicted stability lobe diagrams in X and Y directions based on the vibration mode associated 
(a)  (b)
with the spindle structure. (a) Stability lobes in X direction, (b) Stability lobes in Y direction. 
Figure 10. Predicted stability lobe diagrams in X and Y directions based on the vibration mode associated 
Figure 10. Predicted stability lobe diagrams in X and Y directions based on the vibration mode
with the spindle structure. (a) Stability lobes in X direction, (b) Stability lobes in Y direction. 
In  order  to  clarify  the  effect  of  linear  guide  preload,  the  dynamic  response  of  the  milling 
associated with the spindle structure. (a) Stability lobes in X direction, (b) Stability lobes in Y direction.
machine was also assessed from harmonic analysis in which the contact stiffness of the linear guide 
In  order  to  clarify  the  effect  of  linear  guide  preload,  the  dynamic  response  of  the  milling 
modulus was assumed as 850 N/μm, a higher value corresponding to medium preload. As shown in 
machine was also assessed from harmonic analysis in which the contact stiffness of the linear guide 
In order to clarify the effect
Figure 11, the dynamic  of linear guide preload, the
compliances at lower frequency  dynamic response of the milling machine
are affected to vary with the change of the 
modulus was assumed as 850 N/μm, a higher value corresponding to medium preload. As shown in 
was also assessed from harmonic analysis in which the contact stiffness of the linear guide modulus
Figure 11, the dynamic 
was assumed as 850 N/µm,compliances at lower frequency 
a higher value correspondingare affected to vary with the change of the 
to medium preload. As shown in Figure 11,
the dynamic compliances at lower frequency are affected to vary with the change of the preload of
Appl. Sci. 2016, 6, 76 10 of 12

Appl. Sci. 2016, 6, 76 
Appl. Sci. 2016, 6, 76        
10 of 13
10 of 13
linear guides on the X and Y axis. The maximum compliance in X direction is 0.58 and 0.61 µm/N
preload of linear guides on the X and Y axis. The maximum compliance in X direction is 0.58 and 
preload of linear guides on the X and Y axis. The maximum compliance in X direction is 0.58 and 
for the0.61 
linear
0.61  guide set at medium and low preload; while the maximum compliance in Y direction is
m/N for the linear guide set at medium and low preload; while the maximum compliance in Y 
m/N for the linear guide set at medium and low preload; while the maximum compliance in Y 
0.325 direction is 0.325 
µm/N (167 Hz)and
direction is 0.325  0.352 µm/N (131 Hz).
m/N (167 Hz) and 0.352 
m/N (167 Hz) and 0.352  m/N (131 Hz). 
m/N (131 Hz). 

(a)  (b)
(a)  (b)
Figure 11. Comparisons of the tool end FRFs predicted for milling machine with different preloaded 
Figure 11. Comparisons of the tool end FRFs predicted for milling machine with different preloaded
linear guides mounted on spindle head and movable column. (a) FRFs in X direction, (b) FRFs in Y 
linearFigure 11. Comparisons of the tool end FRFs predicted for milling machine with different preloaded 
guides mounted on spindle head and movable column. (a) FRFs in X direction, (b) FRFs in
direction. 
linear guides mounted on spindle head and movable column. (a) FRFs in X direction, (b) FRFs in Y 
Y direction.
direction. 
The  influence  of  the  linear  guide  preload  on  the  machining  stability  can  be  observed  from 
Figure  12,  which  presents  the  stability  lobes  in  the  X  and  Y  directions.  This  also  compares  the 
The influence of the
The  influence  linear
of  the  guide
linear  guide  preload
preload on on the
the  machining stability
machining  stability  can
can  be be observed
observed  from
from 
difference of the limited cutting  depth when the linear guides are preloaded at different amounts. 
FigureFigure 
12, which presents
12,  which 
The limited cutting  presents thethe 
depth  stability
for  stability  lobes the X
lobes inin the X  and
and  Y Y directions. 
directions.This  This also
also 
stable  machining in X‐direction is 4.2 and 5.6 mm for linear guides  compares
compares  the  the
difference of the limited cutting 
difference of the limited cutting depth when the linear guides are preloaded at different amounts. 
depth when the linear guides are preloaded at
with  low  and  medium  preload,  respectively  and  the  limited  depth  in  Y‐direction  is  10.1  and  10.6  different amounts.
The limited cutting 
The limited
mm, cutting depth
respectively.  depth 
for for 
Comparison  stable 
stable of  machining in X‐direction is 4.2 and 5.6 mm for linear guides 
machining
the  results in X-direction
from  is 4.2 and
stability  analysis  5.6 mm
indicates  that for
the linear
milling guides
with  low  and  medium  preload,  respectively  and  the  limited  depth  in  Y‐direction 
machine has a different limited cutting depth for stable machining in X and Y directions, which are 
with low and medium preload, respectively and the limited depth in Y-direction is 10.1 and is  10.1  and 10.6
10.6 mm,
mm,  respectively.  Comparison  of  the  results  from  stability  analysis  indicates  that  the  milling 
also affected to change with the preload of the linear guides in spindle head. As found, the milling 
respectively. Comparison of the results from stability analysis indicates that the milling machine has a
machine has a different limited cutting depth for stable machining in X and Y directions, which are 
machine  with  high  preloaded  linear  guides  has  a  larger  cutting  depth  as  compared  to  that  with 
limited cutting depth for stable machining in X and Y directions, which are also affected to
differentlower preloaded guides. 
also affected to change with the preload of the linear guides in spindle head. As found, the milling 
change with
machine  the preload
with  of the linear
high  preloaded  guides
linear  in spindle
guides  head.cutting 
has  a  larger  As found,
depth  the
as milling
compared  machine
to  that with
with high
Stability lobes diagram in X-direction Stability lobes diagram in Y-direction
preloaded linear guides has a larger cutting depth as compared to that with lower preloaded guides.
lower preloaded guides. 
10
19
17
8 Stability lobes diagram in X-direction Stability lobes diagram in Y-direction
(mm)depth, (mm)

10 15
Cutting depth, (mm)

19
6 13
17
8 11
Cutting

159
Cutting depth, (mm)

4
Cutting depth,

Preload Z0 Preload ZA 137

6 Preload Z0 Preload ZA
2 115
0.20 0.25 0.30 0.35 0.40 0.50 0.55 0.60 0.65 0.70 0.75 0.80
4 9
Spindle speed, (rpm)x1000 Spindle speed, (rpm)x1000
Preload Z0 Preload ZA 7 Preload Z0 Preload ZA
(a)  (b)
2 5
0.20 0.25 0.30 0.35 0.40 0.50 0.55 0.60 0.65 0.70 0.75 0.80
Spindle speed, (rpm)x1000 Spindle speed, (rpm)x1000
(a)  (b)

Figure 12. Comparisons of the stability lobe diagram predicted at the vibration mode associated
with machine tool structure with different preloaded guideways. (a) Stability lobes in X direction,
(b) Stability lobes in Y direction.
Appl. Sci. 2016, 6, 76 11 of 12

5. Conclusions
This study employed the finite element modeling technology to investigate the machining stability
of a horizontal milling machine with a movable column on hybrid guideway mechanism. Currently,
a number of studies based on finite element methods have been employed to analyze the dynamic
behavior of a machine tool with different configurations. As mentioned above, a realistic model should
be created to reflect the various characteristics of different components such as the linear guide system
and spindle bearing system. In this study, a full FE model of the milling machine with a hybrid
guide system was created in this way. Apart from the machine frame, the linear components such as
linear roller guides were also simulated by solid elements and interface elements at the sliding/rolling
interfaces. These interfaces were respectively characterized by appropriate contact properties, which
were determined based on associated mathematical models according to their preloaded status. A solid
spindle-bearing model, which was experimentally verified by means of physical spindle, was also
incorporated into the machine frame model. The full FE model is different from the rigid-flexible
coupling models in which reduced FE model of the main modules were coupled at the connection
joints with spring elements. The coupled FE model provides a relevant approximation of the dynamic
properties and less vibration modes because of the reduced degree of freedoms in each flexible body.
Whereas the full FE machine model can offer accurate visualizations on the dynamic behaviors of the
spindle system and machine structure. According to the finite element simulation, the fundamental
vibration modes relating to the spindle module are dominated by the feeding mechanisms of the
movable column and the spindle ram. The frequency response of the milling tool shows two apparent
characteristics, including the lower modes dominated by the yawing vibration of the spindle ram
coupled with the twisting vibration of the movable vertical column, and the higher modes associated
with the bending of the spindle shaft.
The machining stability based on the machine structure mode allows the cutter to operate with
high axial depth under lower spindle speed, while the machining stability based on spindle structure
mode is valid for a high speed machine with less cutting depth. In addition, in this case the horizontal
spindle head with low preloaded linear guides show a lower cutting depth for stable machining than
that with higher preloaded guides. As a conclusion, the realizations on the dynamic behaviors of a
milling machine based on the proposed FE model can provide valuable design improvements of the
machine structure or guideway system of the machine tool.

Acknowledgments: We gratefully acknowledge the support for this work provided by National Science Council
in Taiwan through project number MOST103-2221-E-167-004.
Author Contributions: Jui-Pin Hung contributed to the organization of the research work as well as the analysis
of the machine system and manuscript preparation. Wei-Zhu Linand Yong-Jun Chen contributed to the design
and analysis of the machine structure. Tzou-Lung Luo conducted the experimental work of the spindle systems.
Conflicts of Interest: The authors declare no conflict of interest.

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