Virtual machine tool

This paper presents current state of Virtual Machine Tool Technology and related ongoing research challenges. The structural analysis of machine tools using Finite Element models and their experimental calibration techniques are presented. The kinematic analysis and optimisation of machine tool elements are discussed with sample examples. The interaction between the control of the feed drives, cutting conditions and machine tool structure is presented. Multi-body dynamic models of the machine, which allow integrated simulation of machine kinematics, structural dynamics and control techniques, are discussed. The interaction between the machine tool, controller and cutting process disturbances are discussed with sample examples. The simulation of machining operation and its impact on the dynamics of the machine tool and CNC are elaborated. The paper presents both the summary of current and past research, as well as research challenges in order to realise a fully digitised model of the machine tool.

[1]  Yusuf Altintas,et al.  High speed CNC system design. Part III: high speed tracking and contouring control of feed drives , 2001 .

[2]  Mikel Zatarain,et al.  Modular Synthesis of Machine Tools , 1998 .

[3]  Yusuf Altintas,et al.  End Milling Force Algorithms for CAD Systems , 1991 .

[4]  Günter Pritschow,et al.  “Hardware in the Loop” Simulation of Machine Tools , 2004 .

[5]  Wolfgang Neithardt,et al.  Integrierte Topologie- und Gestaltoptimierung in der virtuellen Produktentwicklung , 2001 .

[6]  J.-P. Merlet.  The importance of optimal design for parallel structures , 1999 .

[7]  Yusuf Altintas,et al.  High Speed CNC System Design. Part II : Modeling and Identification of Feed Drives , 2001 .

[8]  Yusuf Altintas,et al.  Generalized Modeling of Mechanics and Dynamics of Milling Cutters , 2001 .

[9]  Kornel Ehmann,et al.  Machining Process Modeling: A Review , 1997 .

[10]  Jean-Pierre Kruth,et al.  Nc-Postprocessing And Nc-Simulation For Five-Axis Milling Operations With Automatic Collision Avoidance , 1999 .

[11]  J. Strenkowski,et al.  Finite element prediction of chip geometry and tool/workpiece temperature distributions in orthogonal metal cutting , 1990 .

[12]  Manfred Weck,et al.  Abgleich der dynamischen Eigenschaften numerischer Modelle mit realen mechanischen Strukturen , 1999 .

[13]  Yusuf Altintas,et al.  An Improved Time Domain Simulation for Dynamic Milling at Small Radial Immersions , 2003 .

[14]  Anath Fischer,et al.  New Trends in Rapid Product Development , 2002 .

[15]  Jean-Pierre Merlet.  DEMOCRAT: A DEsign MethOdology for the Conception of Robots with parallel ArchiTecture , 1997, Robotica.

[16]  Knut Großmann.  Die digitale Simulation für den Entwurf der Werkzeugmaschine , 2004 .

[17]  Elisabetta Ceretti,et al.  Application of 2D FEM to chip formation in orthogonal cutting , 1996 .

[18]  M. F. Zaeh,et al.  Finite Element Modelling of Ball Screw Feed Drive Systems , 2004 .

[19]  Yusuf Altintas,et al.  Open Architecture Modular Tool Kit for Motion and Machining Process Control , 1998 .

[20]  Yusuf Altintas,et al.  A Solid Modeller Based Milling Process Simulation and Planning System , 1994 .

[21]  Kazuo Yamazaki,et al.  Open Controller Architecture – Past, Present and Future , 2001 .

[22]  Gabriel Zachmann.  VR-Techniques for Industrial Applications , 1998 .

[23]  Bert Lauwers,et al.  CAD/CAM based generation of collision free robot programs through the integration of a virtual machining environment , 2001 .

[24]  Peter Groche,et al.  Method for the Optimization of Forming Presses for the Manufacturing of Micro Parts , 2004 .

[25]  Yusuf Altintas,et al.  Numerical Analysis of Metal Cutting With Chamfered and Blunt Tools , 2002 .

[26]  H. Weule,et al.  Structural Optimization of Machine Tools including the static and dynamic Workspace Behavior , 2003 .

[27]  Yusuf Altintas,et al.  MODELING APPROACHES AND SOFTWARE FOR PREDICTING THE PERFORMANCE OF MILLING OPERATIONS AT MAL-UBC , 2000 .

[28]  R. Schwertassek,et al.  Dynamik flexibler Mehrkörpersysteme , 1999 .

[29]  E.J.A. Armarego,et al.  Computer Based Modelling of Popular Machining Operations for Force and Power Prediction , 1985 .

[30]  Paul Sas,et al.  Towards a mechatronic compiler , 2001 .

[31]  M. Bampton,et al.  Coupling of substructures for dynamic analyses. , 1968 .

[32]  Günter Pritschow,et al.  Verification of machine tool functionality by using hardware in the loop and manufacturing simulation , 2003 .

[33]  Yusuf Altintas,et al.  Virtual Design and Optimization of Machine Tool Spindles , 2005 .

[34]  Bert Lauwers,et al.  Optimal and collision free tool posture in five-axis machining through the tight integration of tool path generation and machine simulation , 2003, Comput. Aided Des..

[35]  Yusuf Altintas,et al.  Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design , 2000 .

[36]  Derek Yip-Hoi,et al.  Cutter Engagement Feature Extraction From Solid Models for End Milling , 2004 .

[37]  R. Cook,et al.  Concepts and Applications of Finite Element Analysis , 1974 .

[38]  Jeffrey G. Hemmett,et al.  Robust Feedrate Selection for 3-Axis NC Machining Using Discrete Models , 2001 .

[39]  Erhan Budak,et al.  Improving Cycle Time in Sculptured Surface Machining Through Force Modeling , 2004 .

[40]  D Spath,et al.  Optimized design with topology and shape optimization , 2002 .

[41]  Allan D. Spence,et al.  Integrated solid modeller based solutions for machining , 2000, Comput. Aided Des..

[42]  Kug Weon Kim,et al.  Development of a thermo-viscoplastic cutting model using finite element method , 1996 .

[43]  Yusuf Altintas,et al.  A General Method for the Modeling of Spindle-Bearing Systems , 2004 .

[44]  Christian Brecher,et al.  Static, dynamic and thermal behaviour of machine tools with regard to HPC , 2004 .

[45]  A. Spence,et al.  Direct calculation of machining parameters from a solid model , 1990 .

[46]  I. Inasaki,et al.  Grinding Chatter – Origin and Suppression , 2001 .

[47]  Thomas Ertl,et al.  Analyzing Engineering Simulations in a Virtual Environment , 1998, IEEE Computer Graphics and Applications.

[48]  Yusuf Altintas,et al.  Analytical Prediction of Stability Lobes in Milling , 1995 .

[49]  Pedro J. Arrazola,et al.  Numerical Cutting Sensitivity Study of Tool-Chip Contact , 2003 .

[50]  Jean-Pierre Kruth,et al.  Efficient NC-Programming of Multi-Axes Milling Machines Through the Integration of Tool Path Generation and NC-Simulation , 2000 .