Modeling of machining operations based on the Virtual Machine Tool concept

This paper focusses on dynamic modeling of machine tools. Particular attention is given to integration of Computer Numeric Control (CNC) model, and interactions with machining process. In real machining conditions, modern machine tools show close interaction between dynamic behavior of mechanical structure, drives, and CNC. Mechatronic simulations are done thanks to an integrated methodology that combines control and Multibody System (MBS) capabilities in a nonlinear Finite Element solver (FEA). Force interactions between cutting tool and workpiece are also considered. To achieve this end, a specialized cutting force element has been developed. It considers dynamics of the tool tip combined with the tool workpiece engagement to generate cutting forces that are applied on the structural model. The capacity of such digital twin model to simulate complex machining operations is demonstrated considering several applications.