The analysis of machine tool behavior includes metrological assessment, representation via simulation, and control issues including feed-back control and setpoint value generation. In terms of measurement technology, a wide range of systems is available for measuring displacements and accelerations. On the simulation side, the ANSYS-based simulation environment MORe, developed in-house, offers a versatile tool for the numerical analysis of the static and dynamic behavior of machine tools and other production systems.
Machine simulation
The efficient simulation of machine tools requires the use of tools that fully cover the specific requirements of machine tools: small deformations, changes in machine configuration, moving interfaces, consideration of controlled drives, and interaction with processes. The MORe simulation environment meets these requirements and thus enables efficient investigation of the static, dynamic, and thermal behavior of the machines. MORe is available to industry as an internal application or as a service.
Machine tool and Robot Control
The demands placed on the accuracy and productivity of machine tools have risen steadily in recent years. Modern measurement and control strategies can be used to further improve behavior at the tool center point (TCP). Taking additional sensors and models into account allows behavior to be improved by exploiting the limits of the mechanical structure.
Improvement of positioning through additional use of acceleration signals
Metrology
Measurement technology is of great importance in manufacturing, especially in the field of machine tools. This involves testing component specifications, assessing movement behavior (static and dynamic) at the tool center point (TCP), and also recording the vibration behavior of the machines as part of experimental modal or operational vibration analyses. The interpretation of the measurement results must be adapted accordingly, depending on whether a machine tool or robot is involved. Extensive experience with the systems under investigation is a prerequisite for this. The results obtained in this way allow weak points to be localized and, if necessary, provide the basis for validating simulation models.
Use of a Renishaw QC20 ballbar measurement system to analyze the motion behavior of an industrial robot after milling operations
Gearing Calculation
Unlike bevel gears, axial displacement of the pinion shaft, e.g. due to thermal influences, is permissible for crown gears. Software developed as part of several projects enables the geometric design of crown wheels and the corresponding tools for different manufacturing processes. The kinematic transmission behavior and the stresses during operation are optimized. Measurement results on manufactured crown wheels can also be taken into account. Currently, the focus of activities is on generating tool movements for the highly productive skiving of crown wheels.
Simulation of crown wheel manufacturing using skiving
top, gray: skiving tool; bottom, green: crown wheel (workpiece)