A forward closed-loop virtual simulation system for milling process considering dynamics processing-machine interactions

In this paper, a closed-loop virtual simulation system has been developed to simulate the milling process considering the interactions between manufacturing processes and machine tool dynamics. The system consists of cutting force module, machining stability module, and surface generation module. The synchronous effects of the machining parameters, tool geometry parameters, and the dynamic performance of the machine tool system are considered in the model, and the instant machine dynamic motion error is compensated in the model as a feedback to correct the cutter trajectories. Instantaneous tool-workpiece contact status is used to calculate cutting force, and the peak-to-peak cutting force plot is used to predict the machining stability in time domain under different depths of cut and cutting speeds. The envelope curve of the cutting tool is used to reconstruct the machined surface texture. Moreover, to verify the feasibility of the proposed system, micro-milling experiments are conducted with results showing that the simulation system enables the effective prediction of micro-milling process such as the cutting forces and machined surface quality. It can be potentially applied in production on processing parameter optimization and surface topography prediction.