Simulation of Machining Operations Using the Virtual Machine Tool Concept

This paper focusses on the dynamic modeling of the machine tool including its Computer Numeric Control (CNC), and its interaction with the machining process. To properly simulate modern machine tools in machining condition, which show close interaction between the dynamic behavior of the mechanical structure, drives, and the CNC, we use an integrated methodology that combines control and MBS capabilities in a nonlinear FEA solver called SAMCEF Mecano. To fully capture the dynamic behavior of the machine, force interactions between the cutting tool and the workpiece are also considered. A strong coupling between the mechatronic model of the machine tool and a machining simulation tool is implemented. A specialized cutting force element has been developed. It considers the dynamics of the tool tip combined with the tool workpiece engagement to generate cutting forces. The use of such digital twin model is demonstrated considering some industrial machining operations.