HPC - Stability Simulation

The prediction of stable process parameters to maximize the productivity of milling machines has been an important field of research for a long time. In the past, simulation tools allowing an assessment of the process stability have been created. Nevertheless, the accuracy of predictions by simulation is not yet high enough to make efficient use of stability simulation in production planning. In this context, the article presents developments in the field of modeling the dynamic machine and process behavior for process machine interaction simulation in the field of high performance cutting processes (HPC). On the process side, a complex force model, which takes into account the effects of a phase shift between force generation and chip thickness variation, is introduced. Also, an analysis of fast-rotating main spindle systems has been carried out, which considers variations in the dynamic compliance behavior at the tool center point (TCP) due to rotor dynamic effects and variation of the bearing rigidity. With the Prime Cut software package, a calculation program is presented, which includes the state of the art and new developments in the field of stability simulation.