Simulation aided design of intelligent machine tool components

By integrating sensors and actuators, intelligent machine tool components can be realized, which allow the monitoring of machining processes and machine tool states and an active influencing of process conditions. In the design and layout of these intelligent machine tool components, their mechanical structure and the functional performance of the sensor and actuator sub-systems have to be optimized. As an example, a sensor and actuator integrated fixture system for clamping large but sensitive aerospace structural parts is presented here. In order to investigate the major influences of design approaches on the behaviour of the workpiece and fixture, especially with respect to vibrations and process stability during milling, multiple test rigs and prototypes for basic analyses and machining tests were developed and realized. Experimental and Finite Element Analysis (FEA) results are presented and discussed. Process simulations were conducted taking the dynamic behaviour of the clamped workpiece at different processing steps into account. This simulation can be used for predicting the limits of the process stability. An approach of sensor and actuator integration is described and test results are shown. The paper introduces a principle design and layout methodology for similar intelligent machine tool components.