Advance modeling of machine tool machining process

The Twin-Control European project [1] aims to develop a simulation system that integrates the different aspects that affect machine tool and machining performance, including lifecycle concepts, providing better estimation of machining performance than single featured simulation packages. This holistic simulation model will be linked to the real machines in order to update itself according to their real condition and to perform control actions that will lead to performance improvements. The focus of this paper is on the dynamic modeling of the machine tool including its Computer Numeric Control (CNC), and its interaction with the machining process. To properly simulate modern high-speed machine tools, which show close interaction between the dynamic behavior of the mechanical structure, drives, and the CNC, it is crucial to build models that represent the flexibility of all components and their interactions [2][3]. To answer such requirements, we use 3D MBS and FEA methods for mechanical aspects, and 1D modeling for the CNC. Even if the concurrent use of these technologies is already used in some industrial sectors, it is quite new in the machine tool industry. This multi-model approach is usually inefficient because of limited integration between the different tools. This paper introduces an integrated methodology that combines MBS capabilities in a nonlinear FEA solver called SAMCEF Mecano [4][5]. It enables accurate modeling of the machine by considering FEA models of the components connected together by a set of flexible kinematical joints. Particular models are implemented to deal with drive-Trains and motors dynamics. To fully capture the dynamic behavior of the machine tool, force interactions between the cutting tool and the work piece are also considered in this model.