Optimisation of Structural Design in Benchtop CNC Milling Machines for Enhanced Performance and Efficiency

This paper presents the design and optimisation of a cost-effective benchtop three-axis CNC milling machine aimed at improving performance and precision. Beginning with a conservative design, topology optimisation using Altair SolidThinking Inspire software was employed. Static and modal analyses revealed significant improvements in the optimised structure's integrity and dynamic performance, confirmed through Finite Element Analysis (FEA) and impact hammer tests. The machine features affordable components and standard PC interfaces, ensuring high performance while maintaining low costs. Accuracy tests, including circularity and straightness assessments, identified optimal spindle speeds and feed rates for precision machining. The optimised design showed reduced static displacement and enhanced vibration resistance, ensuring reliable operations. This CNC milling machine, suitable for educational and small-scale manufacturing environments, offers a compact, affordable and user-friendly tool for teaching CNC operations and programming. The study highlights the importance of structural optimisation in CNC machine design, demonstrating notable performance gains through advanced engineering.