Berechnung von Werkzeugmaschinen

in der ANSYS Umgebung

Roberto Rossetti, CADFEM (Suisse) AG
Machine tool simulation in the ANSYS environment

-1-
Overview

Stiffness analysis Harmonic analysis

Modal analysis
Weight influence

Command control
Transient
structural analysis

MOR4ANSYS,
Model Order
Influence of a temperature Reduction

Transient thermal
analysis

- 2-
Stiffness analysis

Loading
Goal is to create a load case similar to the real loading
Define action and reaction forces at the Tool Cutting Point (TCP),
defining the stiffness loop of the machine-tool
Idealise the liaison of the machine to the ground

- 3 / 38-
Stiffness analysis
Results
Goal is to obtain the maximum amount of information
Deformation plots

Stress plots (giving information about areas to be modified)

Stiffness matrixes (overview of stiffness and crosstalk terms)

- 4 / 38-
Stiffness analysis
Parametric study
Goal is to evaluate the stiffness at different working positions
Simulate the machine-tool at different position

Parameter environment of ANSYS Workbench

- 5 / 38-
Weight Influence on accuracy
Results

Deformation in function of the position

Relative value is determining
Axis makes waves along Z axis

- 6 / 38-
Temperature difference & Accuracy
Concept

What is the influence of a temperature difference on the accuracy?

Lets say the machine-tool is set up at 8am. Room temperature is 22C
During the day, the room temperature rises to 23C. The machine-tool will
change its size due to dilatation. What is the influence on accuracy?

Steps
3D parts are needed to replace bushings, for example so that the spindle
expansion can be taken into account.
As the temperature is uniform,
there is no gradient
no thermal coefficients are needed.

- 7 / 38-
Temperature difference & Accuracy

Definition of the temperature difference.

Important is the displacement difference between tool and workpiece

Total deformation

x-dir. 2.1 m
y-dir. -3.0 m
z-dir. -0.1 m

- 8 / 38-
Modal analysis
Concept

Find the first eigenfrequencies and eigenmodes of the machine tool.

Generally speaking, for a given energy, the higher the eigenfrequency,
the lower the amplitude.
Goal is to
Identify the eigenmodes that might influence the machining process
Find constructive modifications that will change these modes and / or
increase the corresponding frequency.

Steps
Similar to a static analysis
Define point masses replacing non-idealised parts
The liaison to the ground is very important

- 9 / 38-
Harmonic analysis
Concept

The machine is excited over a frequency range by a given force.

Amplitudes and phases are computed
Results accuracy depend greatly on the accuracy of the input force and
on the damping used
Very useful to determine how much an eigenmode will influence the
machining process and to get amplitudes between modes.

Steps
Similar to a static and modal analysis
Define frequency range and sampling.

- 10 / 38-
Harmonic analysis

Important is the displacement difference between tool and workpiece

- 11 / 38-
Transient structural analysis
Concept

The machine is excited by an event. The reaction of the machine-tool is

analysed
Results accuracy depend greatly on the accuracy of the input force and
on the damping used
Useful to assess the machine dynamic properties and non-linear effects

Steps
Define an initial state and an excitation
Damping is important to obtain realistic amplitudes
Perform the transient analysis over a given number of time steps

- 12 / 38-
Transient analysis
Example :

An initial velocity is applied to the Y-axis. The axis is then stopped. This
event excite some eigenmodes. The vibrations are then damped out.
V0

Amplitude

Time

- 13-
Command control
Principle

It is possible to take into account the command control. A specific tool

box is available in ANSYS Mechanical APDL.
Influence of the command control on an harmonic analysis
Response of the machine-tool to command control targets
Response of the machine-tool to external excitations

Electrical
schematic as
ANSYS
elements
S
E FI
R
R VIE ELEME IN/OU COMB
T L
E RUN MISC MECH
E W NTS T TRAN IN37
U E
C IN- P-
S
G
P IN SPLIT P-GLIED SIEN BEAM P-GLIED
O PLOT CONST HAR GLIED
E
R SE IN- T I-
R SCOP I-GLIED MONI MASS D-GLIED
T
I R SPRUNG SCH GLIED
D ES
PLOT IN- C
MOD PT1- D-
D T D-GLIED WING
SENS RAMPE AL GLIED GLIED
PLOT D2- ER PT2- SUMM
IN-SINE
STD
ANIM GLIED GLIED ENGL.
DIFFE
PI- U- SUMME
ATES RENZG
GLIED SENSOR NGL.
TR. PD- V- DIFFERE L
GLIED SENSOR NZGL.
PID- A-
GLIED SENSOR
PT1-
AKTOR
GLIED
PT2- ADDSCO
GLIED PE
CONNEC
T
NEGIER
EN
NODE
TRANSF
ERDOF
DECOUP
37 - 14 / 38-
Command control
Harmonic analysis

The harmonic response of the machine-tool will be influenced by the

command control. Resonances due to the command control are
visible.

Kindly provided by Gebr. Heller Maschinenfabrik GmbH

- 15-
Command control
Transient analysis

The entire system is modelled into ANSYS.

Target position f(t)

Control

Velocity sensor

Position sensor Axis

Spindle Actuator
Motor

Maschine bed

- 16-
Command control
Transient analysis

Scenario 1 : positioning error .

Input curve

Error is the difference between

the input and the output curves
Control

Axis

Maschine bed

- 17-
Command control
Transient analysis

Scenario 3 : response to a force or perturbation.

Input curve

Displacement
Control as an output

F
Axis

Maschine bed

- 18-
 Command control

Time domain Frequency domain

Kreisformtest

Positioning
fr verschiedene Kv- und Kp-Werte

20,00

18,00
Soll
16,00 Ist 1
Ist 2
14,00

12,00

Y
10,00

8,00

6,00

4,00

2,00

0,00
-12,50 -7,50 -2,50 2,50 7,50 12,50
X

Perturbation
damping

19 - 19-
MOR4ANSYS Model Order Reduction
Principle

The main idea is to reduce the size of the model by performing a so

called Model Order Reduction. Mass, Stiffness and Damping matrices
are extracted from ANSYS and then dimensionally reduced to smaller
matrices.

- 20-
MOR4ANSYS Model Order Reduction
Principle

The dimensionally reduced matrices are then imported into Simplorer.

Simplorer permits to idealise a complex system with block
corresponding to different physics.

- 21-
MOR4ANSYS Model Order Reduction
Application

The whole machine-tool system can be idealised into simplorer:

Command control (electrical circuits)
Structural parts (Model Order Reduction)
All scenarios discussed before can be played with this idealisation

- 22-
MOR4ANSYS Model Order Reduction
Advanced application - CHATTERING

The Simplorer model contains :

Command control
Machine-tool model obtained with MOR4ANSYS
Cutting process as mathematical model

- 23-
MOR4ANSYS Model Order Reduction
Advanced application - CHATTERING

The stability of the machining process can be assessed.

not stable

stable

- 24-
 Transient Thermal
Example
Coupled simulation: control of unsymmetrical heating

1 Spindle (machining)
2 Motor
3 Belt drive
4 Bearing
5 Bearing
6 Housing
7 Guideway
8 Housing
9 Spindle (drive)

RED = Heat source

- 25-
 Transient Thermal
Example
Coupled simulation: control of unsymmetrical heating

- 26-
 Transient Thermal
Example
Coupled simulation: control of unsymmetrical heating

- 27-
Thanks!
CADFEM (Suisse) AG
Avenue de Cour 74
1007 Lausanne

Tl.: 021 601 70 80

info@cadfem.ch
www.cadfem.ch