Machine tool design, simulation and dynamics

The dynamic behavior of machine tools strongly impacts the process stability of machining processes and therefore determines the final quality of the workpiece. To improve the dynamic behavior of a machine tool, different models and simulations can be applied during the design process of a new machine tool generation. In this context, virtual prototypes based on digital models of the machine tool allow for efficient simulations of the dynamic behavior and thus are capable of replacing cumbersome measurements on a physical prototype. However, to ensure a sufficient match between the simulations and the real machine tool behavior, accurate models for the individual elements which the machine tool is composed of have to be used. This chapter presents the governing effects as well as suitable models and simulations for an efficient and accurate virtual prototype. First, the design process of a machine tool is discussed. Focusing on the dynamic behavior, the different effects contributing to the overall dynamics of a machine tool are presented next. In the following, suitable models, and simulation methods to represent these effects are explained. Finally, three application examples are given, which show how the resulting virtual prototype can be used to study and improve the dynamic behavior of a commercial four axis machine tool.