Skip to main content
SpringerLink
Log in

Implementation of a process and structure model for turning operations

  • Machine Tool
  • Published:
Production Engineering Aims and scope Submit manuscript

Abstract

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.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9

Similar content being viewed by others

References

  1. Iqbal S, Mativenga P, Sheikh M (2007) Characterization of machining of AISI 1045 steel over a wide range of cutting speeds. Proc IMechE 221:917–926

    Article  Google Scholar 

  2. Van Luttervelt CA, Childs THC, Jawahir IS, Klocke F, Venuvivod PK (1998) Present situation and future trends in modelling of machining operations. Ann CIRP 47(2):587–626

    Article  Google Scholar 

  3. Oxley PLB (1989) The mechanics of machining: an analytical approach to assessing machinability. Ellis Horwood Limited, Chichester

  4. Hoppe S (2003) Experimental and numerical analysis of chip formation in metal cutting. Dissertation RWTH Aachen

  5. Merchant ME (1945) Mechanics of the metal cutting process, II. Plasticity conditions in orthogonal cutting. J Appl Phys 16:318–324

    Article  Google Scholar 

  6. Armarego EJA, Whitfield RC (1985) Computer based modelling of popular machining operations for force and power predictions. Ann CIRP 34:65–69

    Article  Google Scholar 

  7. Altintas Y (2000) Manufacturing automation. Cambridge University Press, Cambridge

    Google Scholar 

  8. Waldorf D, DeVor R, Kapoor S (1999) An evaluation of ploughing models for orthogonal machining. Trans ASME 121:550–558

    Google Scholar 

  9. Wang J, Mathew P (1995) Development of a general tool model for turning operations based on a variable flow stress theory. Int J Mach Tools Manuf 35:71–90

    Article  Google Scholar 

  10. Yen Y, Jain A, Altan T (2004) A finite element analysis of orthogonal machining using different tool edge geometries. J Mater Process Technol 146:72–81

    Article  Google Scholar 

  11. Zaeh MF, Schwarz F (2008) Consideration of tool and workpiece temperatures in a modular cutting force model. In: Proceedings of the 1st International Conference on Process Machine Interactions

  12. Jaspers S, Dautzenberg JH (2002) Material behaviour in conditions similar to metal cutting: flow stress in the primary shear zone. J Mater Process Technol 122:322–330

    Article  Google Scholar 

  13. Zerilli F, Armstrong R (1987) Dislocation-mechanics-based constitutive relations for material dynamics calculations. J Appl Phys 61(5):1816–1825. doi:10.1063/1.338024

    Article  Google Scholar 

  14. Zerilli F (2004) Dislocation mechanics-based constitutive equations. Metall Mater Trans A 35 A:2547–2555

    Article  Google Scholar 

  15. Özel T (2006) The influence of friction models on finite element simulations of machining. Int J Mach Tools Manuf 46:518–530

    Article  Google Scholar 

  16. Childs THC (2006) Friction modeling in metal cutting. Wear 260:310–318

    Article  Google Scholar 

  17. Sartkulvanich P, Koppka F, Altan T (2004) Determination of flow stress for metal cutting simulation: a progress report. J Mater Process Technol 146:61–71

    Article  Google Scholar 

  18. Zaeh MF, Oertli T (2004) Finite element modelling of ball screw feed drive systems. Ann CIRP 53(1):289–293

    Article  Google Scholar 

  19. Zaeh MF, Oertli T (2005) Parametric finite element modelling of machine tool structures. Prod Eng XII(1):129–132

    Google Scholar 

  20. Zäh MF, Schwarz F (2007) Arbeitsraumstudien bei Werkzeugmaschinen - Untersuchung des stellungsabhängigen Strukturverhaltens mit der Finite-Elemente-Methode. ZWF Innovationen im Werkzeugmaschinenbau 102:7–8

    Google Scholar 

  21. Zaeh MF, Oertli T (2004) FEM analysis and control system simulation of ball screw feed drive systems in machine tools. In: Proceedings of NAFEMS Seminar on Mechatronics in Structural Analysis, Paper No. 9

Download references

Acknowledgments

We extend our sincere thanks to the German Research Foundation (DFG) for the generous support of the work described in this paper.

Author information

Authors and Affiliations

  1. Institute for Machine Tools and Industrial Management (iwb), Technische Universitaet Muenchen, Boltzmannstr. 15, 85748, Garching, Germany

    M. F. Zaeh & F. Schwarz

Authors
  1. M. F. Zaeh
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. F. Schwarz
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to F. Schwarz.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Zaeh, M.F., Schwarz, F. Implementation of a process and structure model for turning operations. Prod. Eng. Res. Devel. 3, 197–205 (2009). https://doi.org/10.1007/s11740-009-0158-0

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11740-009-0158-0

Keywords

Search

Navigation