https://doi.org/10.20965/ijat.2008.

p0070

Optimal Structure Design Methodology for Compound Multiaxis Machine Tools – III

Paper:

Optimal Structure Design Methodology for

Compound Multiaxis Machine Tools – III
– Performance Evaluation –
Masamitsu Nakaminami * , Tsutomu Tokuma * , Kazuhiko Matsumoto * ,
Sachinori Sakashita * , Toshimichi Moriwaki ** , and Keiichi Nakamoto ***
*
Manufacturing Technology Department, MORI SEIKI CO., LTD.
201 Midai, Iga, Mie 519-1414, Japan
**
Department of Industrial and Systems Engineering, Setsunan University
17-8 Ikedanaka-machi, Neyagawa, Osaka 572-8508, Japan
***
Department of Mechanical Engineering, Kobe University
1-1 Rokko-dai, Nada, Kobe 657-8501, Japan
E-mail: nakamoto@mech.kobe-u.ac.jp
[Received September 3, 2007; accepted December 2, 2007]

Compound multiaxis machine tools are developed for
machining of high-value-added parts
throughintegrating milling and turning operations.
Due to the complexity of the configuration and the
functional versatility required for a compound
machine tool, machining accuracy, productivity, and
return on investment (ROI) remain to be improved.
Design methodology has been widely studied to design
high-performance compound multiaxis machine
tools. We evaluated their performance in this study,
finding that a V guide effectively improves movement
accuracy in the X, Y, and Z directions. Cutting tests
conducted on the XY-plane, YZ-plane, and an
inclined plane prove that tight circularity is achieved.
Cutting cycle time for an identical part and the same
part compared between conventional and new
compound multiaxis machine tools showed the cutting
cycle time is largely reduced. We also found that new
compound multiaxis machine tools consume less
electricity than a manufacturing system with
equivalent productivity consisting of a 2-axis lathe
and a machining center.
Keywords: compound machine tool, structural design,
box-in-box structure, machining time, electrical power
consumption
1. Introduction
Compound multiaxis machine tools conduct
high-value-added parts machining through integrating
milling and turning operations on a single platform.
Combining the functionality of an NC lathe and a 5-axis
machining center, compound multiaxis machine tools
conduct machining operations on an inclined plane, gear
machining, grinding, and machining of other intricate
parts. The main structure of a compound multiaxis
machine tool is based on a conventional NC lathe
incorporating a Y axis and automatic tool changer (ATC)
components for milling. Due to the complexity of the
configuration and the functional versatility required for a
compound multiaxis machine tool, machining accuracy,
productivity, and high initial investment remain to be
improved over conventional NC lathes and machining
centers. We proposed a design methodology for a
compound multiaxis machine tool to resolve these
issues.
We evaluated machining accuracy and productivity
for a compound multiaxis machine tool developed based
on design methodology reported previously [1-3]. Our
ultimate goal is to establish comprehensive design and
evaluation methodology for compound multiaxis
machine tools.
2. Compound Multiaxis Machine Tool
Table 1, Figs. 1, and 2 show specifications and the
configuration of the newly developed compound
multiaxis machine tool [4].
Two spindle headstocks are located at the two ends of
the bed and two spindles drive the workpiece to rotate
with respect to the C axis (Fig. 2). A tool spindle (The
No.1 tool post in Fig. 2) and a turret (The No.2 tool post)
are located above and directly below the center line of
the two workpiece spindles. The No.1 tool spindle
moves in the X, Y, and Z axis directions and rotates with
respect to the B axis. An automatic tool changer and a
tool magazine with maximum capacity of 100 tools are
assigned to this tool spindle. The No.2 tool post with a
maximum of 12 tools travels in the X and Z directions.
The No.2 spindle head (Fig. 2) moves in the Z direction,
enabling the workpiece be transferred from the No.2
spindle head to the No.1 spindle head. The rotation of the
two workpiece spindles is controlled by the C axis.
Simultaneous 5-axis machining is done by combining
X, Y, Z, B, and C axis movement.

Int. J. of Automation Technology Vol.2 No.1, 2008 71

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Nakaminami, M. et al.
Table 1. New compound multiaxis machine tool.
Fig. 1. Newly developed compound multiaxis machine
tool.
Fig. 2. New compound multiaxis machine tool
configuration.
To increase machining accuracy and productivity,
driving for moving parts is applied to their mass centers,
reducing vibration [5].
The conventional drive uses a single ball screw drive
to drive the spindle head (Fig. 3). Driving acts apart from
the mass center due to the distance between the line of
force and the mass center, so considerable rotational
moment acts on the drive spindle head, affecting the
stability of the movement of the moving part. The newly
72
Fig. 3. Comparison of linear axis movement drive.
(a) Single screw drive
(b) Driven at the center of gravity
Fig. 4. Comparison of residual vibration.
developed machine uses two identical ball screw drives
located symmetrically at both sides of the mass center
eliminating rotational moment around the mass center,
enabling the moving part to gain high travel speed.
In a comparison of two driving methods in Fig. 3
(Fig. 4), vibration amplitude and attenuation time are
measured in the X, Y, and Z directions when rapid
traverse on the Y axis is stopped. Because of the mass
inertia of the moving part in the Y axis direction,
dynamic stiffness is comparatively lower than in the
other two directions.
Int. J. of Automation Technology Vol.2 No.1, 2008
 Optimal Structure Design Methodology for Compound Multiaxis Machine Tools – III

Fig. 5. Y axis structure. Fig. 7. Cutting test setup for circularity verification.

Fig. 6. Straightness of Y axis positioning.

Overshoot 0.2 second long and with a magnitude of

7 mm is observed in the conventional drive (Fig. 4). The
movement on the Z axis is much improved by the new
design, which has excellent dynamic characteristics in
the vibration in the X, Y, and Z directions.
A box-in-box structure is used for the compound
multiaxis machine tool [1-3]. The Y axis drive uses a
quill structure, so the mass center varies with the position
on the Y axis, requiring measures to keep the
straightness of movement throughout the stroke along
the Y axis. A V guide (Fig. 5) maintains straightness and
good dynamic characteristics [6], yielding a straightness
of 6.6 mm / 420 mm (Fig. 6).

3. Machining Accuracy Verification

Circular cutting tests conducted to evaluate the
circularity of a round machined workpiece [7] (Fig. 7)
Cut the outer surface of the workpiece using an endmill
as follows:
Tool : 16 mm diameter, 4 flute cemented carbide tool
Workpiece : 57 mm diameter, Brass
Tool rotation speed : 8000 min -1
Feed rate : 2000 mm/min
Depth of cut : 0.05 mm
Figure 8 shows measured circularity results –
2.16 mm on the XY plane and 2.30 mm on the YZ plane.
In the plane inclined 45 degrees to the Z axis, circularity
Fig. 8. Results of new multiaxis machine tool circularity
test.
is 2.34 mm. These results suggest that the new compound
multiaxis machine tool has machining accuracy
equivalent to conventional machining centers. The fact
that machining accuracy on the inclined plane is almost
the same as on the XY and YZ planes shows that the
rigidity of each axis is well optimized.
In circular cutting test results by a conventional
compound multiaxis machine tool [8] At 1,000 mm/min

Int. J. of Automation Technology Vol.2 No.1, 2008 73

Nakaminami, M. et al.

Fig. 10. Test workpiece.

Fig. 9. Results of conventional multiaxis machine tool Table 2. New compound multiaxis machine tool cycle
circularity test. time.

(Fig. 9), circularities on the XY plane is 8.27 mm and

12.89 mm on the YZ plane. Compared to test results in
Fig. 8, the new compound multiaxis machine tool has
machining accuracy 4-5 times higher than the
conventional compound multiaxis machine tool even
under higher cutting feeds.
Use of the box-in-box structure, the V guide, and
driven at the center of gravity thus results in the new
compound multiaxis machine tool’s higher machining
accuracy.

4. Productivity Verification

We compared the productivity of the newly

developed compound multiaxis machine tool to that of a
conventional compound multiaxis machine tool cutting
brass workpieces with an outer diameter of 60 mm in
(Fig. 10). Two machining operations were conducted for
the newly developed and conventional compound
multiaxis machine tools, with the first machining
operation conducted using the No.1 workpiece spindle,
then the part transferred to the No.2 workpiece spindle Table 3. Comparison of idle time.
for the second machining operation, using the two tool
spindles simultaneously. Machining includes inner/outer
diameter cutting, end-face turning, drilling, milling, and
end milling on the inclined plane [6]. The NC program
used is identical for both machine tools. Major
machining conditions are as follows:
Number of tool changes for the No.1 tool spindle
: 12 times
Number of tool changes for the No.2 tool spindle
: 11 times
Maximum rotational speed of the No.1 tool spindle The machining time is 337.7 s and that for the
: 8000 min -1 conventional compound multiaxis machine tool 460 s.
Maximum rotational speed of the No.2 tool spindle Productivity using the new machine increased by 36%.
: 4000 min -1 Table 2 shows the machining time for each
Maximum rotational speed of the No.1 and the No.2 machining operation conducted on the No.1 and 2
workpiece spindle : 4500 min -1
workpiece spindles, including tool change time.
Rotational speed for plunging : 1098 min -1
Machining time reduction generally depends on the
Rotational speed of the No.1 tool spindle for tapping
: 1527 min -1 following 4 factors:
Rotational speed of the No.2 tool spindle for tapping A : Increase in rapid travel speed
: 796 min -1 B : Reduction in tool change time

74 Int. J. of Automation Technology Vol.2 No.1, 2008

 Optimal Structure Design Methodology for Compound Multiaxis Machine Tools – III
Table 4. Cycle time comparison between conventional and
new machines.
Table 5. Targeted of cycle time reduction ratio.
Table 6. Comparison of power and spindle speed.
C : Increase in depth of cut
D : Increase in cutting speed
The same NC program is used for the new and
conventional machine tools, so the depth of cut and
cutting speed are the same, contributing to reducing
cutting time. Rapid travel speed and tool change time are
the two dominant factors determining the reduction in
total machining cycle time. Times for rapid travel and
tool change are called non-cutting or idle time.
Int. J. of Automation Technology Vol.2 No.1, 2008
Fig. 11. Comparison of power consumption between
conventional and compound machine.
Table 3 compares non-cutting time between
conventional and new multiaxis machine tools. In
another example using an Aluminum A5056 workpiece
(Table 4), the productivity of the new compound
multiaxis machine tool was 1.22 times higher than that
of the conventional one under the same machining
conditions.
When the operation rate and machining time are
assumed the same for machining of a typical part using
different machines, such as a 2-axis lathe, and the
conventional and new compound multiaxis machine
tool, the new one must achieve shorter machining cycle
time to obtain equivalent payback within the same
period. We concluded the previously [1-3] that
machining cycle time for the new tool should be 1.3
times shorter than that of a 2-axis lathe, 1.5 times shorter
than that of a multiaxis turning machine, and 1.15 times
shorter than that of a 4 axis lathe (Table 5).
When differences in machine tool specifications are
taken into account (Table 6), machining cycle time can
be further reduced for the new compound multiaxis
machine tool and hence productivity increased 1.22-1.36
times.
5. Energy Consumption and Productivity
As discussed, if the new compound multiaxis
machine tool has shorter cycle time and higher
productivity due to faster rapid travel speed, the shorter
the tool change time, the larger the depth of cut, and the
higher the cutting speed. Energy consumption may
increase, however, using larger drive motors. We use
productivity per unit energy consumption to discuss the
75
Nakaminami, M. et al.

new tool’s energy efficiency.

Mechanical drive efficiency is related to movement Name:
Masamitsu Nakaminami
accuracy, witch in turn is determined by static and
dynamic characterics. In our energy efficiency Affiliation:
evaluation of the new tool (Fig. 11), machining time is MORI SEIKI CO., LTD.
11953 seconds and electricity consumed is 13201 Wh
when a 2-axis lathe and a machining center are used to
cut the part. The new tool took a machining time of 7479
seconds and consumed 10315 Wh of electricity.
We thus found the new compound multiaxis machine Address:
tool machines the workpiece in shorter machining time 201 Midai, Iga, Mie 519-1414, Japan
and consumes 21 % less electricity than conventional Brief Biographical History:
macinging equipment. 1982- Joined MORI SEIKI CO., LTD.
2004- Entered Kobe University
Main Works:
6. Conclusions · “Design Methodology for Basic Structure of Compound Multi-axis
Machine Tools –Analysis of Requirements and Specifications–,”
Memories of Graduate School of Science and Technology Kobe Univ.,
Our evaluation of the performance of a new 24-B, pp. 1-8, 2006.
compound multiaxis machine tool developed based on Academic Societies & Scientific Organizations:
previously proposed design methodology showed that · The Japan Society of Mechanical Engineers (JSME)
cutting tests on the XY-plane, YZ-plane, and inclined · The Japan Society for Precision Engineering (JSPE)
plane achieved tighter circularity with the new machine · The Society of Plant Engineers Japan (SOPE-J)
and greatly reduced cutting cycle time, when the
identical part is cut using the same part program. We also
found that the new tool consumes less electricity than a
manufacturing system using a 2-axis lathe and a Name:
machining center, which has productivity equivalent to Tsutomu Tokuma
the new machine.
In summary, the new machine achieves higher Affiliation:
MORI SEIKI CO., LTD.
machining accuracy, higher productivity, and lower
electricity consumption because of its innovative
cofiguration.

References: Address:
[1] M. Nakaminami, T. Tokuma, T. Moriwaki, K. Nakamoto, “Optimal 201 Midai, Iga, Mie 519-1414, Japan
Structure Design Methodology for Compound Multiaxis Machine Brief Biographical History:
Tools-I –Analysis of Requirements and Specifications–,” 1996- Joined MORI SEIKI CO., LTD.
International Journal of Automation Technology, Vol.1, No.2, Academic Societies & Scientific Organizations:
pp. 78-86, 2007. · Society of Manufacturing Engineers (SME)
[2] M. Nakaminami, T. Tokuma, K. Matsumoto, S. Sakashita, T.
Moriwaki, K. Nakamoto, “Optimal Structure Design Methodology
for Compound Multiaxis Machine Tools-II –Investigation of Basic
Structure–,” International Journal of Automation Technology, Vol.1, Name:
No.2, pp. 87-93, 2007. Kazuhiko Matsumoto
[3] M. Nakaminami, T. Tokuma, and T. Moriwaki, “Design
Methodology for Basic Structure of Compound Multiaxis Machine Affiliation:
MORI SEIKI CO., LTD.
Tools –Analysis of Requirements and Specifications–,” Memories of
Graduate School of Science and Technology Kobe Univ., 24-B,
pp. 1-8, 2006.
[4] MORI SEIKI CO., LTD. Catalogue, NT Series JA04_L0, 2005.
[5] K. Hiramoto, “Driven at the Center of Gravity for Machining
Accuracy and Speed,” Nikkan Industrial Press Machine Design, Address:
2004. 201 Midai, Iga, Mie 519-1414, Japan
[6] W. R. Moore, “Foundation of Mechanical Accuracy,” Internatioanl Brief Biographical History:
Machinary Co. Ltd., pp. 35-51, 1970. 1994- Joined MORI SEIKI CO., LTD.
[7] M. Weck and K. Teipel, “Measurement and Evaluation of Machine Academic Societies & Scientific Organizations:
Tool Dynamics,” Machinist Press, pp. 142-146, 1980. · Society of Manufacturing Engineers (SME)
[8] MORI SEIKI CO., LTD. Catalogue, MT2000a1, 2001.

76 Int. J. of Automation Technology Vol.2 No.1, 2008

 Optimal Structure Design Methodology for Compound Multiaxis Machine Tools – III

Name: Name:
Sachinori Sakashita Keiichi Nakamoto

Affiliation: Affiliation:
MORI SEIKI CO., LTD. Assistant Professor, Department of
Mechanical Engineering, Graduate School of
Engineering, Kobe University

Address: Address:
201 Midai, Iga, Mie 519-1414, Japan 1-1 Rokko-dai, Nada, Kobe 657-8501, Japan
Brief Biographical History: Brief Biographical History:
1995- Joined MORI SEIKI CO., LTD. 2004- Research Associate, Kobe University
Academic Societies & Scientific Organizations: 2007- Assistant Professor, Kobe University
· Society of Manufacturing Engineers (SME) Main Works:
· “Automatic Production Planning System to Achieve Flexible Direct
Machining,” JSME International Journal Series C, Vol.47, No.1,
pp. 136-143, Mar., 2004.
Academic Societies & Scientific Organizations:
· The Japan Society of Mechanical Engineers (JSME)
Name:
Toshimichi Moriwaki
· The Japan Society for Precision Engineering (JSPE)

Affiliation:
Professor, Department of Industrial and
Systems Engineering, Graduate School of
Engineering, Setsunan University

Address:
17-8 Ikedanaka-machi, Neyagawa, Osaka 572-8508, Japan
Brief Biographical History:
1968- Research Associate, Kobe University
1974- Associate Professor, Kobe University
1985- Professor, Kobe University\\
2007- Professor, Setsunan University (Professor emeritus, Kobe
University)
Main Works:
· “Ultrasonic Elliptical Vibration Cutting,” CIRP Annals – Manufacturing
Technology, Vol.44, Issue 1, pp. 31-34, 1995.
Academic Societies & Scientific Organizations:
· The International Academy for Production Engineering (CIRP)
· The American Society of Mechanical Engineers (ASME)
· The Japan Society of Mechanical Engineers (JSME)
· The Japan Society for Precision Engineering (JSPE)

Int. J. of Automation Technology Vol.2 No.1, 2008 77

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