An integrated prediction model including the cutting process for virtual product development of machine tools

Abstract Recently activities for shortening the development time of machine tools and demands for high-value products are consistently being increased. As a result, many studies for predicting the performance in design stage have been conducted to solve these issues. So far, most manufacturers of machine tools have verified designs excluding the cutting process, even though the main performance is the machining quality of the workpiece. Therefore, it has been required to consider together the cutting process model for analyzing the machining quality before the manufacturing of the prototype. This paper presents an integrated dynamic model considering the all interaction of the machine structure, the control system, and the cutting process. The modal truncation technique using the steady-state dynamic analysis in a selected location and frequency range of interest is applied to increase the efficiency of mechatronics simulations including the cutting process. In particular, this proposed prediction model allows accurate design verifications for high-speed machines because it reflects the influences of the high inertia forces and the contour errors caused by high feed rate. Several peripheral milling applications were demonstrated in order to show the feasibility of the proposed prediction model, and we confirmed the superiority of prediction by comparing the simulated and measured results in high feed milling.