Machine tool syntheses in virtual machining

It is beneficial to realize the cutting forces generated in the early stages of the design and process planning. This paper describes the concept of machine tool/process modelling for virtual machining purposes. It is based on the dynamic model of a machine and the cutting process. The model can be used in virtual manufacturing systems (VMS) where computer models that depict the manufacturing process are integrated to form an overall model to portray the real machining system. Modelling can be considered as a very important step in design, performance evaluation, model based monitoring/diagnostics, adaptive control and in design sensitive studies. Computer aided engineering (CAE) systems provide engineers with many design and analysis tools, by combining solid modelling programs with analytical tools, such as finite element codes and dynamic simulation programs, for a specific task. However a model for virtual machining should encompass a total solution. As an example, a CNC machining centre is modelled herein by the integration of Computer Aided Control System Design (CACSD), Computer Aided Multi–Body Dynamic and Finite Element Modelling tools for Machine Tool/Process Modelling (MPM). The derived model includes a regenerative force, cutting process as the interacting phenomena between the spindle and feed axes where dynamic deflection of the elastic parts are included.