Getting the real value out of the simulation of machine tools means:
- Early identification of resonance points
- Get up to 40% more stiffness in a few hours
- Massive material savings and transportation costs reduction
- Higher number of pieces per hour with the same surface quality
- Discover and understand the last secrets of your own machines
- Strenght proof of screws and welds with realistic loads from the whole machine simulation
- Dynamic motion profiles with coupled controller/structure simulation
- Get the milling process, vibration and controller behavior under one roof to clear the last uncertainties before CAD drawings are printed.
The typical process of a dynamic FE simulation of a machine tool is described in the following link and illustrated with videos: Process of a dynamic simulation.
How realistic can a simulation be?
The VDMA recently published the results of a study on the subject of (FE) simulation in mechanical engineering. According to the VDMA study, simulation in mechanical engineering still has much untapped potential.According to the VDMA study, simulation in mechanical engineering still has much untapped potential. Many companies do not use simulation at all. Others only hire external service providers to obtain the desired added value through simulation.
The word "simulation" is a generic term for many types of simulation. Among other things, a simulation means modelling, calculation and visualisation of different physical processes.
We at Meshparts have been working with a special kind of simulation for more than 17 years: Finite Element Simulation. And we do this again almost exclusively in the field of structural dynamics. So we are highly specialised in a niche segment of simulation.
Our experience with FE-simulation of complete machines can be explained in short or long terms. We summarize the short version here.
In worst-case scenarios (no previous experience with the corresponding machine and no comparisons with previously made measurements) we achieve the following accuracies:
- The calculation of the static stiffness of complete machine tools has an accuracy compared to measurements of ±1%.
- The calculation of the natural frequencies of complete machine tools has an accuracy compared to measurements of ±10% in a frequency range of 0-2000 Hz.
- The prediction of amplitudes in frequency responses of complete machine tools is afflicted with an accuracy of ±30% in a frequency range of 0-2000 Hz.
- The simulation of traversing profiles of complete machine tools (coupled controller-mechanics simulation) has an accuracy of ±40% compared to measurements.
- The simulation of process forces under consideration of controlled, dynamic movements and vibrations of the entire machine is possible with good informative value, but is associated with a relatively high effort.
For this to work in practice, specialized tools are necessary (more on this below).
And that brings us to the real reason for the whole demonstration:
The simulation of machines can only develop its maximum added value through regular use in your company.
What can we offer you?
With the Meshparts software you produce reliable and reproducible results with consistent quality.
The special feature of our solution is an assembly oriented FE software with integrated FE model library.
