Abstract
The present paper discusses the numerical condensation of a finite element model of a three-axis high speed milling machine to a low-order state-space model suitable for control system design. In order to analyse the dynamic characteristics of the machine within the whole working domain, the dynamics of the machine in different spatial configurations should be investigated without the time consuming complete recalculation of the machine dynamics. The paper shows that a multi-stage component mode reduction and synthesis procedure provides a solution to that problem, because it allows a cheap analysis of different configurations. Substructures with known dynamic characteristics are described by their respective component modes. They are combined in the appropriate relative positions, and the system is solved through a reduced set of equations for each configuration. A well-considered selection of the types of component modes improves the quality of the reduced model.
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