Integrated Simulation of Machine Tool and Process Interaction for Turning (original) (raw)

The interaction between process and mach ine tool behaviour can lead to process instabilities in terms of self-excited vibrat ions where the energy of the machine tool oscillat ion is gene rated by process excitation. The regenerative chatter effects lead to wavy surfaces on the workpiece. This effect has been simulated for turning processes with an integrated simulation approach , which couples a time doma in simulation model for the mach ine tool and the workp iece with an analyt ical turn ing model. In this paper a procedure is illustrated for coupling an FEAbased 3-dimens ional turning model with the time doma in model for the machine tool under cons ideration of the resulting workp iece surface. In comparison to an analytical approach for calculating the mechanical tool load, the 3D-FEA-model has the potent ial to determine the resulting cutting forces for even complex-shaped tool geometries, e.g. a complicated chip breaker or a varying cutting edge radius on the main or minor cutting edge. As a matter of the huge model size the calcu lation time in particular for 3-dimensional problems is comparatively long to analytical cutting force models. Therefore, in this paper an approach to reduce the calculation time by using characteristic diagrams for the calculated process forces in the FEA-model is presented. The research has also been focused on the current major problem in the FEAbased modelling that the thrust and feed forces are generally underestimated in the simulation.