Design Improvement of Machine Tools by Integration of Cutting Process

Model into Finite Element Analysis (FEA)

Prof. Dr.-Ing. Gerhard Kehl

ELACTAM, Havana
customer:
22.2. – 24.2.2016 „increase stable
cutting depth“ Deckel Maho Gildemeister DMG 635 V eco
Machine Tool Production, Operation
and Conditions

machine tool = automated production machine

The relative movement between workpiece and tool results
in the predeterminated geometry of the workpiece.

⇒ The quality of machine tools is a success factor for the

quality and quantity of workpieces and products.
⇒ Simulation methods can be applied during the design
process in order to improve machine tools.
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 Milestones of FEA Application in Machine Tools
Example: HELLER Maschinenfabrik GmbH, Nürtingen, Germany

deformation
portions of spindle rotor
virtual components dynamics
frequency precision topology integration integration of
statics response test optimization of drive control cutting process

time ?
1997 1999 2000 2002 2004 2006 2008 2010 2016
discretization of damping effects ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒
model reduction thermal simulation ⇒ ⇒ ⇒ ⇒ ⇒
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 Integration of Drive Control in FEA

motivation - realistic simulation of mechatronical reference and disturbance

behavior in frequency and time domain
measured compliance frequency response (tool vs. workpiece)
mechanics + drive + control = mechatronic
compliance

interaction

not controlled controlled

frequency
• considerable influence of control on low-
frequency response
• mechanic is „left alone“ at high frequencies
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 Integration of Drive Control in FEA
Example: Choosing the position measurement systems

Question: Which position measurement systems have to be employed and what are
the most adventageously locations for them ?

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 Integration of Drive Control in FEA
Example: Machining centre with different levellers
FEA-integrated mechanics frequency response
A [ dB ] = transfer behaviour between direct
P-position and 20
PI-velocity control position sensor and drive encoder
10

stiff and 0
undamped 1 10 100 1000
-10

elastomer coupling
foundation
-20

ball screw
-30

90

soft and

phi [°]
damped 0
1 10 100 1000

-90

-180

-270
frequency [Hz]

behaviour of feed drive control with stiff and undamped

levellers
⇒ strong limitation of position control gain KV
exemplary behaviour:
⇒ soft and damped levellers improve KV by 80%
compensation of force step (relative between
reference: Heller + Bertuch + Bilz
tool and workpiece) by feed drive control
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 Integration of Cutting Process in FEA
Initial Situation

regenerative chatter in regenerative chatter in

turning milling

chatter no chatter chatter no chatter chatter

effect of instable cutting machine dynamics

• bad surface quality

• abnormal tool wear
• fractured cutting edges process dynamics
„wave-on-wave cutting“
• damage of machine
• poor productivity reference: Bosch + Heller + Pratt & Whitney +
WZL Aachen + ISF Dortmund
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 Integration of Cutting Process in FEA
Initial Situation

„Which design allows higher

cutting depth / process stability / V1 V4
V2 V5
productivity ?“ V3 V6

method 1
stability charts gained from
unstable
experiments (very cost-intensive)

e.g. six spindle designs

designing
+ producing
stable
+ assembling
+ testing (cutting process)
spindle speed [1 / min]

costs > 100.000 € MCi16_HSM_Y

H1_MoSpi_HSZ_Y

173 MCi16_Vision_LEH_Y
135
MCi16_neu_SpiLa_steif_Spindelhals_Stufe_Stahl_Y
174 585
459 549 740 Gamfior_1_Y
904
616 813 Kessler SpiLaMCi16_Y
182
614 860
956 H1_2000_1_Y 1285
896
766 MCi26_12500_Y
1300 1354
1293
method 2 1066 1394

trying to evaluate simulated 1122

compliance frequency responses

(uncertain speculation !)
reference: Heller
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 Integration of Cutting Process

motivation - increase system process stability (incl. tool, workpiece, fixture)

- reduce cost-intensive tests (in design and startup phase)
unstable
cutting depth

stable
spindle speed
Δx(t)

ΔF(t)

cutting force model

method 3
• integration of linearized cutting force models for milling and turning in FEA
• loops of transient calculations over tool rotation increment ⇒ over cutting depth ⇒ over spindle speed
• stability criterion: increasing / decreasing chip thickness modulation
• chatter frequency from spectral analysis ⇒ relevant vibration mode ... ⇒ design measure reference: Heller
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 Conclusion

• The application of FEA has

– speeded up the design process of machine tools,
– reduced the number of physical prototypes,
– increased the customers benefit.

• Integration of further details (control, cutting process models) leads to more realistic
simulation of the machine tool behaviour.

• Present focus:
Usage of process stability and surface quality as evaluation criteria in the design
process of machine tools
⇒ optimization of mechanical structure with new design target:
increasing stable cutting depth

• The method is applied in the design process of machining centers (since 2010) at
Gebr. HELLER Maschinenfabrik GmbH, Nürtingen, Germany, http://www.heller.biz

Thanks for listening. Questions ?

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