Abstract
The dynamic performance of the machine tool system plays an important role on the machining process. On the other hand, it is difficult to consider the machine tool’s dynamic performance in the previous cutting simulation method. In this paper, a novel simulation method for the interaction simulation between the machining process and machine tool structure is presented. The influence of the dynamic performance of machine tool structure on the machining process and the interaction between them are considered by simplifying the machine tool structure in a novel finite element cutting simulation model. This model is used for potassium dihydrogen phosphate (KDP) crystal machining simulation; the chip formation and the waviness prediction are realized, and the simulation results agree well with the experiments, which provide the evidence and accuracy of this presented method.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
Brecher C, Esser M, Witt S (2009) Interaction of manufacturing process and machine tool. CIRP Ann Manuf Technol 58:588–607
Abele E, Weigold M, Rothenbucher S (2007) Modeling and identification of an industrial robot for machining applications. Ann CIRP 56(1):387–390
Asad M, Mabrouki T, Memon AA et al (2012) Three-dimensional finite element modeling of rough to finish down-cut milling of an aluminum alloy. Proc IMechE B J Eng Manuf 227:75–83
Felicia CJ, Galle T, Waele WD et al (2012) FEA modeling of orthogonal cutting of steel: a review. Sustainable Construction and Design 3:98–105
Kim JS, Lee BH (1991) An analytical model of dynamic cutting forces in chatter vibration. Int J Mach Tools Manuf 31:371–381
Altintas Y (2000) Manufacturing automation: metal cutting mechanics, machine tool vibrations, and CNC design. Cambridge University Press,Cambridge
Altintas Y, Kersting P, Biermann D et al (2014) Virtual process systems for part machining operations[J]. CIRP Ann Manuf Technol 63(2):585–605
Bisu CF, Laheurte R, Dranis P et al (2012) Dynamic behavior characterization of the milling tool during the cutting process, Vol III. Proceedings of the World Congress on Engineering, London
Piendl S, Aurich J (2006) FEM simulation of chip formation coupled with process dynamics. J Manag Eng 220:1597–1604
Paolo A, Nicola C, Giacomo B et al (2012) The effects of dynamic interaction between machine tool subsystems on cutting process stability. Int J Adv Manuf Technol 58:923–932
Kehl G (2014) Design improvement of machine tools by integration of cutting process model into finite element analysis. The 3rd International Conference on Design Engineering and Science, Pilsen
Brecher C, Bäumler S, Guralnik A (2013) Machine tool dynamics-advances in metrological investigation, modeling and simulation techniques, optimization of process stability. Proceedings of the 5th Manufacturing Engineering Society International Conference, Zaragoza
Marsh ER, Arneson D, Doren MV et al (2006) Interferometric measurement of workpiece flatness in ultra precision fly cutting. Sens Rev 26:209–217
Chen WQ, Sun YZ, An CH, et al (2014) Modeling and simulation of the interaction of manufacturing process and machine tool structure in flycutting machining. Proc IMechE C J Mech Eng Sci. doi:10.1177/0954406214563962
Taylor JS, Carlisle K, Klingmann JL et al (2010) Precision engineering within the National Ignition Campaign. Proceedings of the euspen International Conference, Delft, pp 248–255
Wang W, Li KY, Wang J et al (2011) Analysis on dependence of phase matching angle on temperature in KDP crystal. Opt Laser Technol 43:683–686
Li KY, Jia HT, Wang CC et al (2009) Theory and experiment analysis of factors affecting THG efficiency for the TIL prototype laser facility. Optik 120:1–8
Auerbach JM, Wegner PJ, Couture SA et al (2001) Modeling of frequency doubling and tripling with measured crystal spatial refractive index nonuniformities. Appl Opt 40:1404–1411
LiangYC CWQ, Bai QS et al (2012) Dynamic design approach of an ultra-precision machine tool used for optical parts machining. Proc IMechE B J Eng Manuf 226:1930–1936
Chen WQ, Liang YC, Sun YZ et al (2014) Design philosophy of an ultra-precision fly cutting machine tool for KDP crystal machining and its implementation on the structure design. Int J Adv Manuf Technol 70:429–438
Liang YC, Chen WQ, Bai QS et al (2013) Design and dynamic optimization of an ultraprecision diamond flycutting machine tool for large KDP crystal machining. Int J Adv Manuf Technol 69:237–244
Oliver WC, Pharr GM (1992) An improved technique for determining hardness and elastic modulus using load and displacement sensing indentation experiments. J Mater Res 7(6):1564–1583
Lin ZC, Lai WL, Lin HY et al (2000) The study of ultraprecision machining and residual stress for NiP alloy with different cutting speeds and depth of cut. J Mater Process Technol 97:200–210
Lo S-P, Lin YY (2002) An investigation of sticking behavior on the chip–tool interface using thermo-elastic–plastic finite element method. J Mater Process Technol 121:285–292
Dao M, Chollacoop N, Van KJ et al (2001) Computational modeling of the forward and reverse problems in instrumented sharp indentation. Acta Mater 49:3899–3918
Zong WJ, Li ZQ, Zhang L et al (2013) Finite element simulation of diamond tool geometries affecting the 3D surface topography in fly cutting of KDP crystals[J]. Int J Adv Manuf Technol 68(9–12):1927–1936
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The authors declare that there is no conflict of interest.
Rights and permissions
About this article
Cite this article
Chen, W., Liu, H., Sun, Y. et al. A novel simulation method for interaction of machining process and machine tool structure. Int J Adv Manuf Technol 88, 3467–3474 (2017). https://doi.org/10.1007/s00170-016-9068-4
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-016-9068-4