Implementation of a process and structure model for turning operations

The consideration of the dynamic interaction between the machine tool structure and the cutting process is a prerequisite for the simulative prediction and optimization of machining tasks. However, existing cutting force models are either dedicated to already examined manufacturing operations or require extensive measurements for the determination of cutting coefficients. In this context this paper outlines a modular, analytical cutting force model applicable to common turning processes. It takes into account the dynamic material behavior, nonlinear friction ratios on the rake face as well as heat transfer phenomena in the deformation zones. On the part of the machine tool structure a parametric model based on the Finite Element Method (FEM) is implemented. Both models are coupled for the simulation of process and structure interactions, whereas the influence of the control system is considered as well. The simulation results were verified experimentally on a turning center.