Abstract
Problem statement: Machines dynamic performance depends not only upon the mechanical structure and components but also the drives and control system. However, the design of the machines is still at the nascent stage by working on an individual machine basis, hence lacks generic scientific approach and design guideline. Approach: Using computer models integrated drives and control system to predict the dynamic performance of ultra-precision machine tools can help manufacturers substantially reduce the lead time and cost of developing new machine. This study proposed a holistic integrated dynamic design and modeling approach, which supports analysis and optimization of the overall machine dynamic performance at the early design stage. The modeling and simulation process on an ultra-precision lathe machine tool is presented using the proposed approach. Results: Model of an ultra precision machine tool is established and used to predict the overall machine performance of the configuration. Deformations of base and fixed sideways in motion are calculated to demonstrate the valid of the method. Conclusion: Excellent accuracy on motion deformation is achieved. The designed and implemented integrated time-domain dynamic analysis and modeling system can predict the static and dynamic performance of ultra-precision machine tools, which can reduce the lead time and the cost of developing new machine.
Highlights
Development of new engineered product offers several opportunities for the use of simulation and computational modeling
A typical design and manufacturing cycle requires the product first to be modeled using Computer Assisted Design (CAD) software, as either a solid model or a B-rep model, which can be used for geometric analysis
The model is represented in Computer-Assisted Manufacturing (CAM) software, typically as a solid model, to determine the optimal tool path for machining
Summary
Development of new engineered product offers several opportunities for the use of simulation and computational modeling. The same product needs to be represented in ComputerAssisted Engineering (CAE) software, typically as a finite element mesh, which can be used to conduct distortion analysis during and after manufacturing. The model is represented in Computer-Assisted Manufacturing (CAM) software, typically as a solid model, to determine the optimal tool path for machining. The CAD-CAECAM-CNC model should be instead to a more efficient approach, Zaeh and Siedl (2007) has proposed a new method for simulation of machining performance by integrating finite element and multi-body simulation for machine tools, but the control system in the machine has not been taken into considered. A drives and control system integrated modeling and analysis approach for time-domain dynamic analysis is proposed and employed in evaluation of an ultra-precision machine. The dynamic performance can be evaluated in visualized illustrations for the weakness point of the machining, such as every part stress or strain in working, which can used to be expressed clearly on an existed machining
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