Predicting regenerative chatter in milling with hardware-in-the-loop simulation using a dexel-based cutting model

• DOI: 10.1007/s11740-021-01040-8
• Publication Date: 2021-04-08T14:03:06Z
• Authors: Sascha Röck
• Keywords: Machine tool; Cutting tool; Position (finance)

Abstract This article proposes a new model for simulating the interaction between cutting process and machine tool in real-time. The purpose of is to be coupled with real CNC (by using hardware-in-the-loop simulation) order consider forces predict regenerative chatter vibrations during virtual commissioning. Therefore dexel-based workpiece adaptive resolution used computation chip thickness respectively based on actual position machining progress workpiece. Several simulation experiments are performed validate analyze its numerical limits, such as computational accuracy efficiency. capability proven by comparing simulated critical depth cut an analytical solution stability lobes. dynamics were approximated single degree freedom (SDOF) oscillator. A concluding analysis real-time factor confirms model’s ability integrated under hard requirements cycle times just few milliseconds which typical CNCs.