Simulation and measurement of environmental influences on machines in frequency domain

Mayr, Josef; Ess, Markus; Pavliček, Florentina; Weikert, Sascha; Spescha, Daniel; Knapp, Wolfgang

doi:10.1016/j.cirp.2015.04.001

Cited by 12 publications

(3 citation statements)

References 2 publications

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“…Time-and energy-inefficient warming-up phases or complicated temperature control strategies produce significant costs, along with potential rejects. During the summer months, temperature fluctuations of 5 to 15 Kelvin during the day occur, which increases the need for a suitable correction procedure [7][8][9]. Consequently, the performance of the machine tools falls short of what is theoretically possible [10].…”

Section: Introduction and State Of The Artmentioning

confidence: 99%

Correction of Thermal Errors in Machine Tools by a Hybrid Model Approach

Friedrich,

Geist,

Yaqoob

et al. 2024

Applied Sciences

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Thermally induced position errors are one of the main error sources on the workpiece caused by the behavior of the machine tool. In today’s industrial environment, the correction of thermal errors is usually based on simple regression approaches, where the characteristic diagrams for correction are generated experimentally. The performance of these approaches is only valid for the corresponding load regimes, which often results in insufficient correction quality in practical applications. Consequently, there is only a limited benefit or even a deterioration in machine behavior if the correction characteristic is based on an inapplicable load case compared to the initial experiment. Simulation-generated characteristic diagrams using finite element models solve this disadvantage, but do not answer the question about the choice of the right characteristic matching the current load situation, and, in addition, calculate very slowly. Structural model-based correction using reduced models, on the other hand, calculates quickly, but requires a high modeling effort for accurate correction. The approach, presented in this contribution, combines simulation-generated characteristic diagrams and a structural model-based decision algorithm for a new hybrid model in order to select the appropriate characteristic diagram for the present load situation in the control system. This paper presents the simulative characteristic diagram generation by a finite element model validated by experiments in a climate chamber and a validated structural model including the concept for the decision algorithm.

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Section: Introduction and State Of The Artmentioning

confidence: 99%

Correction of Thermal Errors in Machine Tools by a Hybrid Model Approach

Friedrich,

Geist,

Yaqoob

et al. 2024

Applied Sciences

View full text Add to dashboard Cite

show abstract

“…Besides, it is preferred that the temperature of CCW is able to vary quickly along with the pre-set power curve of motors, rather than conventional motor cooling with CCW of constant temperature. In the applications of the electrical spindle cooling of optical machining [6][7][8], a CCW temperature control response time of tens of seconds of is also demanded, to achieve "servo" thermal management Appl. Sci.…”

Section: Introductionmentioning

confidence: 99%

Temperature Fluctuation Attenuation of Circulating Cooling Water Using Dynamic Thermal Filtering

Cui

Tan

et al. 2020

Applied Sciences

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The Demand for circulating cooling water (CCW) with high temperature stability and a quick response to temperature control is essential for precision engineering, so a dynamic thermal filtering method is proposed in this paper. Some CCW is bypassed, blocked, and used as a thermal capacity medium, and the temperature fluctuation of CCW is significantly reduced by heat exchanging with the medium. The temperature of the medium dynamically follows the set value of the CCW temperature by real time updating, and so realizes a quick CCW temperature control response. The attenuation ratio of temperature fluctuation was derived, theoretically validating the effectiveness of the method. The experimental results indicate that a CCW temperature fluctuation attenuation ratio of tens of dB (−3.47 dB, −6.91 dB, −10.97 dB and −15.28 dB corresponding to temperature fluctuation frequencies of 0.01 Hz, 0.025 Hz, 0.053 Hz and 0.105 Hz, respectively) is achieved by the proposed method. The updating time of thermal capacity medium is 82 s, which means that the temperature fluctuation attenuation remains functionally valid when the set value of CCW changes. The proposed method is low cost in operation and provides an effective approach to satisfy the challenging demand for CCW with high stability and a good dynamic temperature control performance.

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“…Joint distributions are not considered. Mayr et al [2015] analyze the effect of temperature on a three-axis machine tool. A mathematical model is used to locate the tip of the machining tool in a 3D space.…”

Section: Consideration Of the Thermal Effects On Dtmentioning

confidence: 99%

A new method of rigid assemblies stochastic 3D tolerance analysis including thermal performance.

Umaras¹

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Positional and orientation tolerances are specified in the components of a mechanical assembly and are of great importance in design, as they affect its quality, reliability, and cost. Tolerance analysis is a method of stacking the tolerances parts of an assembly to achieve an overall value in a given direction. The opposite approach is tolerance synthesis, or allocation, where the tolerances of the components are adjusted through a determined criterion for compliance with design constraints or for optimization purposes, such as cost reduction. The tolerance synthesis is generally performed when the results of a tolerance analysis process do not reach a design constraint requirement. The aim of this thesis is to propose a new method for tolerance analysis in a three-dimensional domain, including manufacturing simulation and consideration of functional thermal effects. A case study involving an internal combustion engine shows the efficacy of the method. Manufacturing simulation based on the Monte Carlo method provides a statistical distribution representation of process variation along a specified tolerance range. This resource can lead to optimization of the tolerance range of the mechanical assembly in each orthogonal direction and can also be a significant aid in design decisions and the selection of manufacturing processes. A feature of the proposed method is the consideration of geometric position tolerances as a function of orientation tolerances. The feature results in great accuracy at a high manufacturing volume. The method is application-oriented and can be applied effectively in the industry.

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Simulation and measurement of environmental influences on machines in frequency domain

Cited by 12 publications

References 2 publications

Correction of Thermal Errors in Machine Tools by a Hybrid Model Approach

Correction of Thermal Errors in Machine Tools by a Hybrid Model Approach

Temperature Fluctuation Attenuation of Circulating Cooling Water Using Dynamic Thermal Filtering

A new method of rigid assemblies stochastic 3D tolerance analysis including thermal performance.

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