Académique Documents
Professionnel Documents
Culture Documents
State of the art, problems and trends in the simulation of machine tools Prof. Dr.-Ing. Christian Brecher Chair of Machine Tools, WZL RWTH Aachen, Germany
Virtualization of the machine tool development Product developement process with virtual prototypes
concept Konzept
engineering
testing Erprobung
optimization Optimierung
startup
concept Konzept
engineering
testing Erprobung
development time
Implementation of
commissioning
WZL/Fraunhofer IPT Seite 2
fz ae ap
Concept development
Component design
Machine construction
Coupled simulation
Input: stiffness
Input: ...
Output
Fstat
Q(t) Fdyn
WZL/Fraunhofer IPT
Seite 4
Model
Simulation result
Static deformation and stress caused by external forces Dynamical problems cannot be calculated
WZL/Fraunhofer IPT
Z-ram 44,0%
Seite 5
Model
Simulation results
Eigen modes and Eigen frequencies The amplitude of the oscillation cannot be calculated
WZL/Fraunhofer IPT Z Y X
Frequency: 42.4 Hz
Frequency: 73.4 Hz
Frequency: 102.0 Hz
Seite 6
f5 = 102 Hz f4 = 73 Hz f1 = 42 Hz
Model
Y X
10
-2
Simulation results
Frequency response function Calculation in time domain possible
WZL/Fraunhofer IPT
20
40
60
140
160
180
200
Seite 7
Investigation of damping effects within a cluster Dresden, Munich, Aachen, DFG Project FOR 1087
Damping in mechanical systems is the
irreversible transformation of mechanical energy in other forms of energy. Loss of energy by fluids Loss of energy by friction Loss of energy in solid bodies F
3 2 1/6 1 2 4
Components Damping
F
3
of the spindle
x
4 5 6
x
5
Bearings
Roller Guide 1 Rolle 35 Ball Guide 1 90 35 80 RollerKugel55 Guide 2 Rolle 70 Ball Guide 2 Kugel 55
60 50 40 30 20 10 0
Ball bushes
Ball Screw
Guides
compliance
compliance
k m x F
k m d x F
frequency
WZL/Fraunhofer IPT
frequency
Vertikal Vertical
Horizontal Horizontal
Horizontal
Seite 8
Q FT L
LT
LF
Model
Simulation result
deformation caused by stationary temperature distribution The distribution of the temperature over the time is not calculated
WZL/Fraunhofer IPT
The thermal-equivalent force FT compensates for the change in length L of a body caused by a change in temperature T. 1 LT = LT T L = AE LFT FT = AET
Seite 9
173W
Not depicted: Additional heat sources in: drives, bearings & losses due to splashing of the oil
Q(t) Model
a3
Simulation result
deformation caused by in stationary temperature distribution
WZL/Fraunhofer IPT
LN PQ P M H J K G= 30 M= 36 H H O J H= 31 N= 37 I G R I = 32 O= 38 I J= 33 P= 39 K= 34 Q= 40 H L= 35 R= 41 I J I J KK
Environment temperature 21C
= 25 m
Deformed structure Seite 10
Cluster project Dresden, Chemnitz, Aachen: DFG-Transregio 96 Thermo-energetic Design of Machine Tools
Motivation: Conflict between accuracy, productivity and energy input
Productivity Accuracy
Energy Input
Correction
Calculating inverse set points for a controlinternal adjustment of the target or rather the actual value for position control of feed axes based on models and experiments
Compensation
Physically influencing the causes by components integrated into assembly groups for muting or rather reducing thermally caused effects at the tool center point
Structure integrated sensors Controlled heat flow
Construction material
Seite 11
cred
kinematic elements
k ges
FEM
DBS
G e k o p p e lte M e h rk rp e rs im u la tio n (M K S )
MKS
Weg, Geschwindigkeit
Weg, Geschwindigkeit
Weg, Geschwindigkeit
S c h n itts te lle
x, x
FA
TCP path
Interaction
Kraft
x, x
S c h n itts te lle
FA
[M]; [K];[C]
WZL/Fraunhofer IPT
x, x
S c h n itts te lle
FA
TCP path
Schnittstelle
Schnittstelle
Interaction
-
DBS
DBS
DBS
Flexible MBS
co simulation
Seite 12
FEM + analytics
MBS + analytics
(t) F (t)
Coupled simulation
WZL/Fraunhofer IPT Seite 13
unstable
y
n x
stable
spindle speed
F (t)
Uncertainties
FEM modeling of the exact dynamic Cutting force model Cutting force coefficients Process kinematic Tool geometry Work piece behavior
Uncertainties
Fy
Fz
Fx
WZL/Fraunhofer IPT
Seite 14
process behavior
phase
Cutting depth
bearing calculation
direct and crosscompliance boundary conditions n, F, preload,
Fv d(Fv) d d(Fa) axial bearing displacement
Extended simulation of spindlebearing systems considering nonlinear bearing characteristics and varying bearing stiffness to provide FRF at operation conditions
axial force Fa
Fa
stiffness
radial
spindle
Fexc.
Calculation of non-linear
bearing stiffness
Simulation of static and dynamic system behavior Consideration of bearing system characteristics
Consideration of load,
WZL/Fraunhofer IPT
Seite 15
Tt
Cutting Edge 1
Complex Force Model
Tt
Tt
Tt
Cutting Edge 2
Complex Force Model
G [m/N]
Tt
n]
n[ 1/m i
Tt
f [Hz]
1 n z
Tt
Tt +
Nominal Force
n
fz
Fz Fy Fx
Tt 1 n z
Cutting Edge n
Complex Force Model
ae ap
Tt
Tt
WZL/Fraunhofer IPT
Seite 16
HSK-T
PSC
TS
WZL/Fraunhofer IPT
Seite 17
Revolver-integration
tilting
n HSK-T
MB MA bending moment MB
PSC
TS
WZL/Fraunhofer IPT
Seite 18
Machine reaction
Software, testing
Status bits
Controller simulation
VMCP completed
Optimization of drive settings requires
VNCK VPLC
Virtual drives
Outputs
Inputs
virtual drives: Inputs: PLC and NC software versions NC setup archives Mechatronic machine model (Simple) drive model Requirements: Adoption of original drive data and drive setup archives Coupling capabilities and interfaces to other models within the virtual machine tool
Seite 19
Who can model and control complex multi-physics problems in an efficient way?
The assembly of a complete FEM-Model becomes
more complicated and expensive Should complete FEM-Models of machine tools be build up in-house or should this FEM-calculation be done by an external supplier?
In-house FEM calculation
Easy optimization of single structure
problem
No license costs
Seite 20
Integrated CAx software with a 1-for-all model Needs and wishes of the end users
Integrated CAx software
One software for the complete production
1-for-all model
The end user dislikes to build up different
process of work pieces or machine systems (CAD, CAE, CAM and CAP)
One software for the design and
different problems
How to build up a target-oriented and efficient CAx software system which can be used in different branches?
WZL/Fraunhofer IPT Seite 21
No
Yes
OK?
Evaluation of the process
Stability (chattering) Tolerances m Surface quality
F(t)
Temperature
max
Thermal-model machine
Optimal NC program
F(t) xd
CAM
Path optimization
NC simulation (VNCK)
Seite 22
machine and process Dimensioning of complex milling and grinding processes Optimising concept for multiaxial NC-path planning
Current work
Integration in CAM-system NX
Further development of milling and grinding simulations (models, algorithms) Structure-dynamic machine modelling Analysis of control performance
WZL/Fraunhofer IPT
Seite 23
task, which needs experienced FEM end users and high quality input data.
Especially the simulation of the dynamic and thermal machine
solutions for an integrated software framework for design, optimization and process planning of work pieces.
WZL/Fraunhofer IPT
Seite 24