Rapid evaluation of machine tools with position-dependent milling stability based on response surface model

Abstract

The milling stability is one of the important evaluation criterions of dynamic characteristics of machine tools, and it is of great importance for machine tools’ design and manufacturing. The milling stability of machine tools generally varies with the position combinations of moving parts. The traditional milling stability analysis of machine tools is based on some specific positions in the whole workspace of machine tools, and the results are not comprehensive. Furthermore, it is very time-consuming for operation and calculation to complete analysis of multiple positions. A new method to rapidly evaluate the stability of machine tools with position dependence is developed in this article. In this method, the key position combinations of moving parts are set as the samples of calculation to calculate the dynamic characteristics of machine tools with SAMCEF finite element simulation analysis software. Then the minimum critical axial cutting depth of each sample is obtained. The relationship between the position and the value of minimum critical axial cutting depth at any position in the whole workspace can be obtained through established response surface model. The precision of the response surface model is evaluated and the model could be used to rapidly evaluate the milling stability of machine tools with position dependence. With a precision horizontal machining center with box-in-box structure as an example, the value of minimum critical axial cutting depth at any position is shown. This method of rapid evaluation of machine tools with position-dependent stability avoids complicated theoretical calculation, so it can be easily adopted by engineers and technicians in the phase of design process of machine tools.