Integrated simulation method for interaction between manufacturing process and machine tool (original) (raw)
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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.
Simulation of Machining Operations Based on the VMT Concept
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The simulation of machining operations in close interaction with the machine tool dynamic behaviour requires two main modelling components. First, to accurately simulate the dynamics of modern high-speed machine tools, a mechanical model that represents the flexibility of all components and their interactions is needed [1]. To create this mechatronic model of a machine tool (virtual machine tool), 3D MBS and FEA methods are used for mechanical aspects and 1D modelling for the CNC. As described in Chap. 2, an integrated methodology is proposed for the mechanical aspects, and it combines MBS capabilities in a nonlinear FEA [2] solver called SAMCEF Mecano [3]. It enables accurate modelling of the machine by considering FEA models of the components connected by a set of flexible kinematical joints. Additional models are implemented to deal with drive-trains and motors dynamics. Furthermore, an integrated cutting force model is used to capture force interactions between the tool and the workpiece to fully capture the dynamic behaviour of the machine tool. Within the scope of the Twin-Control project, the VMT concept was used to model two machines, a high-speed four-axes box-in-box machine from Comau and a large three-spindle five-axes machine from Gepro. The two models are shown in Fig. 11.1. Furthermore, an integrated cutting force model is used to capture force interactions between the tool and the workpiece to fully capture the dynamic behaviour of the machine tool during the machining operations. This chapter deals with the integration of this cutting force model with the developed VMT module.
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Journal of Computational and Applied Mathematics, 2004
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Despite the large number of models of advanced machining processes, such as abrasive waterjet machining (AWJM), which have been developed so far, there still has been confusion about the nature by which workpiece surfaces are eroded. The finite element method (FEM) could provide both qualitative and quantitative means in order to explain the AWJ erosion process. This paper presents an attempt to model the AWJM process using the powerful tool of the finite element method. The main objective is to develop an FE model which would enable to predict the depth of cut without any cutting experiments. In the new model, interaction of the abrasive particle with the workpiece material is traced at small time increments. The model accurately predicts the depth of cut as a result of AWJ impact and the FE results are in good agreement with experimental results.
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Even though there is substantial work on adaptive control within the body of modern control theory, there have been few reductions of parameter adaptive control to actual machine tools on the shop floor. It has been suggested that the primary impediments to such application are the lack of mathematical models of manufacturing processes in forms appropriate to the control problem, and the lack of in-process sensing techniques that would be complementary to such models. This paper describes one step in a sequence of research efforts that is intended to lead to the adaptive control of unattended machine tools. Numerical parameters are used to evaluate coefficients of a previously developed state space model of semi-orthogonal metal cutting on a lathe. An advanced continuous simulation language (ACSL) program is presented.
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This work focuses on the numerical modelling of machining using a three dimensional (3D) approach. Numerical modelling based on finite element method has been widely used for decades in simulation of machining processes. Although most works in the literature have been focused on two dimensional approaches the simulation of real conditions in industrial operations requires 3D formulation in order to reproduce the complex geometry of the tool. In this work 3D modelling is applied to the simulation of finishing turning of Inconel 718, a strategic low machinability Ni alloy commonly used in high responsibility applications. Main objective is analyzing thermo-mechanical variables, difficult to measure during cutting process those are related with the onset and progression of tool wear.<br>
Fundamentals, Methods and Applications, 2012
This research estimated the temperature field in the cutting zone and compared it to the experimental results when machining AISI 5135 steel applied in the automotive industry. The simulation was performed by employing ABAQUS/Explicit R version 6.10-1 which uses a finite element method for spatial discretization of momentum equation and an explicit integration scheme for discretization relative to time. Through this numerical technique various machining parameters can be predicted such as force and temperature. A 2D orthogonal cutting has been modeled using Arbitrary Lagrangian-Eulerian (ALE formulation). The thermo-viscoplastic behavior of the workpiece material is modeled by Johnson-Cook constitutive work flow stress model. The numerical results presented a good agreement to the experimental ones validating them by an error of only ∼ 3%.
Continuous-time simulation of semi-orthogonal metal cutting on a lathe
Computers & Industrial Engineering, 1987
There has been considerable attention to applications of feedback control to machine tools. Certainly all computer numerically controlled (CNC) machines use servomechanisms for the spindle and feed drives. When feedback control is extended to the metal cutting process itself, there has been an unfortunate tendency to call such systems adaptive controls, for example, adaptive control constraint (ACC) .and adaptive control optimization (ACO), even though they have not been adaptive in the sense of modern control theory. A special name, parameter adaptive control, has been proposed to describe the application of truly adaptive control to metal cutting. Even though there is substantial work on adaptive control within the body of modern control theory, there have been few reductions of parameter adaptive control to actual machine tools. It has been suggested that the primary impediments to such application are the lack of mathematical models of manufacturing processes in forms appropriate to the control problem, and the lack of in-process sensing techniques that would be complementary to such models. This paper describes one step in a sequence of research efforts that is intended to lead to the adaptive control of unattended machine tools. Numerical parameters are used to evaluate coefficients of a previously developed state space model of semi-orthogonal metal cutting on a lathe. An Advanced Continuous Simulation Language (ACSL) program is presented.
Effect of tool model on result of finite element simulation of high speed machining
Advances in Manufacturing Science and Technology, 2015
Address: Angelos P. MARKOPOULOS, PhD Eng., Nikolaos I. GALANIS, PhD Eng., Nikolaos E. KARKALOS, MSc Eng., National Technical University o f Athens, School of Mechanical Engineering, Section of Manufacturing, Technology, Heroon Politechniou 9, 15780, Athens, Greece, Witold HABRAT, PhD Eng., Rzeszów Univ ersity of Technology, 12 Powstańców Warszawy Str., 35-959 Rzeszów, Poland EFFECT OF TOOL MODEL ON RESULT OF FINITE ELEMENT SIMULATION OF HIGH SPEED MACHINING (HSM)