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CNC Stiffness Calculator v7
CNC Stiffness Calculator v7
CNC Stiffness Calculator v7
work in progress
X
gress
VERTICAL LOAD CAUSING GANTRY TOP Z BENDING (SAG) &
X DIRECTION CUTTING CAUSING GANTRY TOP TWISTING AND X DIRECTION BENDING
STEP 1. DIAGRAM
depth
width
L gantry length
Z
X
Y
Look up tables
1. Tool cutting forces (cutting material)
Cutting
force (N) Option selected
Wood 5 Cutting force
Alum 50
Steel 75
Add your own . . .
L length 1600 mm
Alum
Construction material
Alum
Cutting material
Option selected
Alum 69000 2.6E-06 24000 69000 2.6E-06 24000
Option selected
BOX SECTION
depth thickness
(= kg x 9.81) x x
width
Geometry> width 80
depth 80
thickness 3
X deflection torsion
from gantry twisting twisting constant K 1369599.00
during X direction cut angular deflection 0.00030423
STEP 4. RESULTS
y
outer diameter
inner dia
thickness
x x
x
mm
mm outer diameter 80 mm
mm inner diameter 74 mm
torsion
twisting constant K 1077313.38
radians angular deflection 0.0003868 radians
deg angular deflection 0.0221616 deg
Nmm/deg torsional stiffness 1128077 Nmm/deg
mm tool deflection 0.1933965486 mm
microns tool deflection 193.39654861 microns
X bending
mm deflection 0.058 mm
microns 57.500469178 microns
X total
mm deflection 0.25090 mm
Tf
depth
depth
x x
x
Tw
width
y
width 80 mm
depth 80 mm width
torsion torsion
twisting constant K 2157.84 twisting constant K
angular deflection 0.19309 radians angular deflection
angular deflection 11.06431 deg angular deflection
torsional stiffness 2259.5 Nmm/deg torsional stiffness
tool deflection 97.772652261099 mm tool deflection
tool deflection 97772.652261099 microns tool deflection
X bending X bending
deflection 0.121 mm deflection
120.69444832223 microns
X total X total
deflection 97.89335 mm deflection
thickness
x depth
x x
y y
width width
80 mm width 12 mm
80 mm depth 80 mm
3 mm half width 6 mm
2498881.3333 mm4
914452 mm4 Ixx TOTAL 512000 mm4
6400 mm2 XS outer
5476 mm2 XS inner
924 mm2 XS total 960 mm2
3413333.3333 mm4 Iyy outer
2498881.3333 mm4 Iyy inner
914452 mm4 Iyy TOTAL 11520 mm4
Z bending
0.133 mm deflection 0.237 mm
132.67 um deflection 236.96 um
1478.84 N/mm stiffness 828.00 N/mm
torsion
1369599.00 twisting constant K 29570.40
0.00030423 radians angular deflection 0.01409067 radians
0.01743211 deg angular deflection 0.80739523 deg
1434135 Nmm/deg torsional stiffness 30964 Nmm/deg
0.1521238595 mm tool deflection 7.04631900748348 mm
152.12385953 microns tool deflection 7046.31900748348 microns
X bending
0.034 mm deflection 2.684 mm
33.810275877 microns 2683.84326355341 microns
X total
0.18593 mm deflection 9.73016 mm
Tw
depth x x
x x
y
Tf ENTER BROCHURE Ixx & Iyy VALUE
y Ixx 600000
wwidth 80 mm
i
d
depth 80 mm width 80
t
h
Tf (flange thickness) 3 mm depth 80
torsion torsion
twisting constant K 2106.00 twisting constant K 1369599.00
angular deflection 0.19784742 radians angular deflection 0.00030423
angular deflection ### deg angular deflection 0.01743211
torsional stiffness 2205 Nmm/deg torsional stiffness 1434135
tool deflection 100.242568 mm tool deflection 0.15212386
tool deflection 100242.568 microns tool deflection 152.12386
X bending X bending
deflection 0.064 mm deflection 0.034
64.2563566 microns 33.8102759
X total X total
deflection 100.30682 mm deflection 0.18593
INPUTS PURPLE
Commercial aluminium profile (Hepco etc.) OUTPUTS YELLOW
x
1. Draw your special shape similar to example shown
URE Ixx & Iyy VALUE 3. Draw a DATUM line at the lowest point on the obje
mm Adjust these 3 parameters 7. The total summed I value for the special shape is s
mm until these values are similar 8. The deflection for this section is then shown below
mm to brochure figures
torsion
twisting constant K
radians angular deflection
deg angular deflection
Nmm/deg torsional stiffness
mm tool deflection
microns tool deflection
mm
microns
mm
mm3
kg
complex shapes (using parallel axis theorem)
rom the centre of each rectangle to this datum into the Neutral Axis table
cation will be calculated, which is quoted as a distance from the arbitrary DATUM
the location of ZERO stress, so stiff shapes have most material far away from this line
his section is then shown below in yellow. These generic solid rectangles can b
14
15
16
b
e generic solid rectangles can be arranged to create more detailed shapes (e.g. 2 pieces of 40x80x3 RHS):
0 -50.00 0 0
0 -50.00 0 0
0 -50.00 0 0
TOTAL I value
mm from datum
Contribution to Ixx (mm4)
563160
301106
301106
8760
31920
101626
101626
564720
0
0
0
0
0
0
0
0
1974024 mm4
Y DIRECTION CUTTING CAUSING GANTRY SIDES CANTILEVER BENDING
STEP 1. DIAGRAM
H height
(mm)
Y direction cutting side thickness
force (N)
Baseframe
Z
Some worked examples . . . .
45
deflection (um)
40
open bearing
profile bearing
35
30
25
20
15
10
0
5 10 gantry side thickness
15 (mm) 20
8
deflection (um)
7
open bearing
profile bearing
3
profile bearing
deflect
6
0
0 50 distance
100 of ballscrew
150away from top
200 of gantry (mm)
250 300
top of
gantry
Look up tables
1. Tool cutting forces
Cutting
force (N) Option selected
Wood 5 Cutting force
Alum 50
Steel 75
Add your own . . .
Shapes list
PLATE SECTION
BOX SECTION
TUBE SECTION
I BEAM
RHS
Channel
STEP 2. LOAD CASE INFORMATION
INPUTS PURPLE
OUTPUTS YELLOW
Boundary conditions: Top end guided (i.e. gantry resists torsion), bottom end simple (open bearing) or fixed (profile rail be
Y LOADS
Height H 300
thickness
Y
Worked example, varying thickness of aluminium sides
5N cutting force (wood)
H height 300mm
X distance to ballscrew 150mm
Plate section sides, 300mm wide, 12mm thick
open bearing gantry side open bearing profile bearing
profile bearing thickness tool deflection tool deflection
(mm) (um) (um)
6 41.516 7.548
9 12.301 2.237
12 5.189 0.944
15 2.657 0.483
18 1.538 0.280000
21 0.968 0.176
24 0.649 0.118
As thickness of sides increases, tool deflection
rapidly decreases then tails off with diminishing
returns
20 25
Option selected
Cutting force Wood 5
Option selected
Alum 69000 2.6E-06 24000 69000 2.6E-06
STEP 3. GANTRY SIDE PLATE GEOMETRY
ALL VIEWS ARE TOP VIEWS OF GANTRY SIDES
ENSURE WIDTH AND DEPTH ARE CORRECTLY ORIENTED RELATIVE TO GANTR
PLATE SECTION
259200
width
mm
mm
depth
width
depth
Ixx TOTAL
STEP 4. Results
Simply supported
open bearings
Gantry/Tooly 0.001
Gantry/Tooly 0.865
BOX SECTION
x
914452
x
thickness
width
depth x
1800 mm width 80 mm
12 mm width 80 mm
thickness 3 mm
esults
ION
0.0008649
n bearings 0.0001573
mm
TUBE SECTION I BEAM
x
537697.776 813146.00 x
outer
diameter
inner dia thickness
width
depth
x
x
thickness 3
sec 2 2600187.33
Ixx TOTAL 537697.776 mm4 Ixx TOTAL 813146.00
cross section outer 5026.548246 mm2
cross section inner 4300.840343 mm2
cross section total 725.707903 mm2 cross section total 702
1270372 x
thickness thickness
width
depth
mm width 120 mm
mm depth 80 mm
mm thickness 3 mm
mm4
mm4 Ixx TOTAL 1270372 mm4
cross section outer 9600 mm2
cross section inner 8436 mm2
mm2 cross section total 1164 mm2
782936.5 thickness
width
depth
width 120 mm
depth 80 mm
thickness 3 mm
0.00029 mm
0.286 um
0.00005 mm
0.052 um
X & Y cutting error (gantry top and sides bending and twisting)
DESIGN STATUS
OK
Borderline
6.19780451349124
NOT OK
DESIGN STATUS
OK
Borderline
0.663357612703755
NOT OK
Y d ire c t io n c u t tin g e rro r (m m )
g and twisting)
value smaller
0.02
0.01
0
-0.25 -0.2 -0.15 -0.1 -0.05 0 0.05 0.1 0.15 0.2 0.25
-0.01
-0.02
-0.03
-0.04
X direction cutting error (mm)
(m m )
Z d eflection (sag )
0.25
cutting accuracy)
value smaller
0.2
0.15
0.2 0.132671522540751
0.1
0.05
0
Max permitted deflection Estimated deflection
ellipse X=A cos t
Y=B sin t
t X Y
0 0.185934 0
10 0.183109 0.00015
20 0.174721 0.000296
30 0.161024 0.000432
40 0.142434 0.000556
50 0.119516 0.000663
60 0.092967 0.000749
70 0.063593 0.000813
80 0.032287 0.000852
90 1.14E-17 0.000865
100 -0.032287 0.000852
110 -0.063593 0.000813
120 -0.092967 0.000749
130 -0.119516 0.000663
140 -0.142434 0.000556
150 -0.161024 0.000432
160 -0.174721 0.000296
170 -0.183109 0.00015
180 -0.185934 1.06E-19
190 -0.183109 -0.00015
200 -0.174721 -0.000296
210 -0.161024 -0.000432
-0.022981 -0.019284
-0.019284 -0.022981
-0.015 -0.025981
-0.010261 -0.028191
-0.005209 -0.029544
-5.51E-18 -0.03
0.005209 -0.029544
0.010261 -0.028191
0.015 -0.025981
0.019284 -0.022981
0.022981 -0.019284
0.025981 -0.015
0.028191 -0.010261
0.029544 -0.005209
0.03 -7.35E-18
Tool deflection due to gantry top BENDING when X AXIS cutting
10000
tool deflection (microns)
2683.84
1000
120.69
100
64.26
57.50
10
BOX SECTION TUBE SECTION I BEAM 80w 80d 3t RHS 80w 80d 3t PLATE SECTION Channel 80w 80d Commercial
80w 80d 3t 80OD 74ID 12w 80d aluminium profile
(Hepco etc.) 80w
80d
Tool deflection in Z DIRECTION due to vertical load (router etc.) deflecting gantry top
250.00
236.96
225.63
tool deflection (microns)
200.00
149.20 149.20
150.00
132.67 132.67
100.00
50.00
0.00
BOX SECTION 80w TUBE SECTION I BEAM 80w 80d 3t RHS 80w 80d 3t PLATE SECTION 12w Channel 80w 80d
80d 3t 80OD 74ID 80d
Tool deflection due to gantry top TWISTING when X AXIS cutting
1000000
tool deflection (microns)
97772.65 100242.57
100000
10000
7046.32
1000
193.40
152.12 152.12
100
BOX SECTION 80w TUBE SECTION I BEAM 80w 80d 3t RHS 80w 80d 3t PLATE SECTION 12w Channel 80w 80d
80d 3t 80OD 74ID 80d
Tool deflection due to gantry sides BENDING when Y AXIS cutting
tool deflection (microns)
1.000
deflection - open bearings
deflection - profile bearings
0.100
0.010
0.86SECTION
PLATE 0.16 BOX0.25 0.0480w
SECTION 0.42SECTION
TUBE 0.08 0.2880w
I BEAM 0.05
80d 3t 0.18
RHS 0.03
120w 80d 3t 0.29120w
Channel 0.05
80d 3t
1800w 12d 80d 3t 80OD 74ID