Dynamic FEM Mesh Generation

Abstract

Today, simulation of production processes is becoming much more important in manufacturing, where complex machining operations and materials handling are encountered. A particular emphasis has been given to research and development of virtual manufacturing, having various computer-aided software tools for analysis and simulation of machine behaviours, aiming at realising an optimal production environment, first-time-right products, yet with high quality, low cost and short lead-time. It often requires an advanced system capability to analyse and simulate the dynamic behaviours of production cells and lines, as if they are under real operating conditions. This type of simulation considers production rate of the entire system while treating each machine as a black box. In order to evaluate and optimise the mechanical integrity and to ensure the true dynamic and thermal behaviours of machine tools, some types of analyses are required for individual machines in addition to system-level simulation. Due to the complex nature of the geometric features of the components and that of the applied loads, finite element method (FEM) and boundary element method (BEM) have been mostly adopted in the last three decades. FEM is a powerful numerical tool for solving mathematical problems related to practical engineering situations. In the past, it was a common practice to over-simplify such problems to the point where an analytical solution could be obtained. Because of the uncertainties associated with such a procedure, large safety factors were introduced in the design of machine tools.