Abstract
Machining processes must be adjusted regarding tolerances in dimension and shape to fulfill product requirements. For this purpose, machine simulations are used to allow a preliminary characterization of the given process, thus minimizing the number of physical prototypes and scrap parts. However, these simulations are either extremely specialized for single problems, e.g., dynamic machine behavior, or they are simplified to a kinematic simulation of the machine without considering the machine behavior at all. This article presents a new approach for a real-time machine simulation by combining four types of simulations to close this gap. This proposed approach uses a voxel-based material removal inside a kinematic machine simulation as input parameters for a cutting force calculation. Afterwards, the forces are applied to a multi-body simulation of the static machine behavior. Starting point of the simulation is a hardware-in-the-loop coupling of a real CNC and a real-time visualization of a virtual machine tool. The simulation is experimental verified by comparing the simulated cutting forces and displacements with the measured forces during the process and the resulting shape of the manufactured work piece. The presented conclusions show the general applicability of the proposed method for the simulation of milling processes.
Highlights
Today, there is an increasing demand of virtual prototypes for product development and for production planning
To further reduce the necessary tests on the machine tool, this paper presents a realtime machine simulation combining a multitude of different simulations of the machine tool
In order to determine the applicability of the presented method, a machine simulation was implemented with real-time voxel material removal, a HIL to a Siemens 840D NC unit, a kinematic and a static machine simulation, including the bending of the end mill
Summary
There is an increasing demand of virtual prototypes for product development and for production planning. A virtual prototype decreases the start-up time of a new product on a machine tool and allows simultaneous producing while planning the process. Even with state-of-the-art process planning, the final commissioning steps for a new product are performed on the real machine tool to prevent erroneous production and unconsidered collisions. The described machine simulation includes a hardware-in-the-loop (HIL) simulation of a real NC unit, a voxel-based material removal, a cutting force calculation, and a multi-body simulation of the machine tool. The focus of this paper lies on the calculation of the cutting forces based on voxel material removal model for a possible real-time application
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