Discrete Cutting Force Model for 5-Axis Milling with Arbitrary Engagement and Feed Direction

Berglind, Luke; Plakhotnik, Denys; Öztürk, Erdem

doi:10.1016/j.procir.2017.03.250

Cited by 19 publications

(11 citation statements)

References 9 publications

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“…The cutting force module [4], originally developed in MATLAB, is converted to a single DLL to be called in the SAMCEF simulation. An overview of the cutting force module structure is shown in Fig.…”

Section: Machining Modulementioning

confidence: 99%

Simulation of Machining Operations Based on the VMT Concept

Cugnon

Delsemme

2019

Twin-Control

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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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Section: Machining Modulementioning

confidence: 99%

Simulation of Machining Operations Based on the VMT Concept

Cugnon

Delsemme

2019

Twin-Control

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“…In the machine tool design stage, the module can calculate end-of-life based on loads provided by a machine tool simulation module [11][12][13] that can provide very accurate component loads. The possibility to use an accurate input to the end-oflife module will, of course, enhance the life predictions and, hence, machine tool designers will be able to select more suitable bearing.…”

Section: End-of-life Calculation Modulementioning

confidence: 99%

New Approach for Bearing Life Cycle Estimation and Control

et al. 2019

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A new approach for the control of the life cycle of rolling bearings in machine tools is presented. The approach is based on a new simulation tool that has been developed using the well-known ISO 281 standard as a reference. This new tool improves the accuracy of the estimations in two fields: model-based and feature-based prognostics. The tool provides accurate end-of-life estimations, thanks to the determination of more realistic component loads for a defined manufacturing cycle. In addition, it can be embedded in monitoring devices using real machine tool usage data and calculate remaining useful life (RUL) of the analyzed component. Experimental tests confirm that the ISO 281 standard overestimates end-of-life of bearings under controlled conditions and presents vibration analysis as a key tool for an early detection of bearing failure. Indeed, the application of the module for remaining useful life calculation should be combined with vibration-based condition monitoring in order to detect unexpected component degradation.

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“…The prediction models and generation of accurate digital twins are a collective modeling effort which requires both detailed modelling of the process and the dynamic machine behaviour. Considering the machining processes, current literature provides accurate models to predict milling process physics [3][4][5]. Rob Ward r.ward@amrc.co.uk Extended author information available on the last page of the article.…”

Section: Introductionmentioning

confidence: 99%

Accurate prediction of machining feedrate and cycle times considering interpolator dynamics

Ward

Sencer

Jones

et al. 2021

Int J Adv Manuf Technol

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This paper presents an accurate machining feedrate prediction technique by modelling the trajectory generation behaviour of modern CNC machine tools. Typically, CAM systems simulate machines’ motion based on the commanded feedrate and the path geometry. Such approach does not consider the feed planning and interpolation strategy of the machine’s numerical control (NC) system. In this study, trajectory generation behaviour of the NC system is modelled and accurate cycle time prediction for complex machining toolpaths is realised. NC system’s linear interpolation dynamics and commanded axis kinematic profiles are predicted by using finite impulse response (FIR)–based low-pass filters. The corner blending behaviour during non-stop interpolation of linear segments is modelled, and for the first time, the minimum cornering feedrate that satisfies both the tolerance and machining constraints has been calculated analytically for 3-axis toolpaths of any geometry. The proposed method is applied to 4 different case studies including complex machining toolpaths. Experimental validations show actual cycle times can be estimated with > 90% accuracy, greatly outperforming CAM-based predictions. It is expected that the proposed approach will help improve the accuracy of virtual machining models and support businesses’ decision-making when costing machining processes.

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Discrete Cutting Force Model for 5-Axis Milling with Arbitrary Engagement and Feed Direction

Cited by 19 publications

References 9 publications

Simulation of Machining Operations Based on the VMT Concept

Simulation of Machining Operations Based on the VMT Concept

New Approach for Bearing Life Cycle Estimation and Control

Accurate prediction of machining feedrate and cycle times considering interpolator dynamics

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