Validation of a Coupled Simulation for Machine Tool Dynamics Using a Linear Drive Actuator

Abstract

In order to ensure high productivity capabilities of machine tools at a low cost but at increased geometric accuracy, modeling of their static and dynamic behavior is a crucial task in structure optimization. The drive control and the frictional forces acting in feed axes significantly determine the machine’s response in the frequency domain. The aim of this study was the accurate modeling and the experimental investigation of dynamic damping effects using a machine tool test rig with three-axis kinematics. For this purpose, an order-reduced finite element model of the mechanical structure was coupled with models of the drive control and of the non-linear friction behavior. In order to validate the individual models, a new actuator system based on a tubular linear drive was used for frequency response measurements during uniaxial carriage movements. A comparison of the dynamic measurements with the simulation results revealed a good match of amplitudes in the frequency domain by considering dynamic damping. Accordingly, the overall dynamic behavior of machine tool structures can be predicted and thus optimized by a coupled simulation at higher level of detail and by considering the damping effects of friction. Dynamic testing with the newly designed actuator is a prerequisite for model validation and control drive parameterization.