Efficient Offline Thermal Modelling for Accurate Assessment of Machine Tool Behaviour

N. S. Mian, S. Fletcher, A. P. Longstaff, A. Myers, C. Pislaru

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

Thermal gradients from internal and external heat sources cause instabilities which affect the machine tool positional accuracy. Positioning error results from deformation of the machine structure due to linear thermal expansions of some machine parts combined with the thermal behaviour of associated complex discrete structures producing non linear thermal distortions. Thermal gradients due to internally generated heat and varying environmental conditions pass through structural linkages and mechanical joints where the roughness and form of the contacting surfaces act as resistance to thermal flow and affect the heat transfer coefficients. Measurement of long term thermal behaviour and associated thermal deformations in the machine structure is a time consuming procedure and most often requires machine downtime and is therefore considered a dominant issue for this type of activity, whether for characterisatio n or correction. This paper presents a novel offline technique using Finite Element Analysis (FEA) to simulate the combined effects of the internal and external heat sources on a small vertical milling machine (VMC). Detailed long term experimental testing of the effects of temperature distribution in the machine structure and in-depth heat transfer work to obtain accurate values of heat transfer coefficients across joints is reported. Simplified models have been created offline using FEA software and the evaluated experimental results applied for offline simulation of the thermal behaviour of the machine structure. The FEA simulated results obtained are in close correlation with the obtained experimental results. FEA simulation enables quick and efficient of fline assessments of temperature distribution and displacement in the machine tool structures along with characterisation of the machine under variable environmental conditions. This results in a significant reduction in machine non productive downtime and can provide significantly more thermal data for the creation and validation of robust long term error compensation models.

LanguageEnglish
Title of host publicationLaser Metrology and Machine Performance IX - 9th International Conference and Exhibition on Laser Metrology, Machine Tool, CMM and Robotic Performance, LAMDAMAP 2009
EditorsK. Cheng
Publishereuspen
Pages9-18
Number of pages10
ISBN (Electronic)9780955308277
Publication statusPublished - 2009

Fingerprint

machine tools
Machine tools
downtime
heat sources
heat transfer coefficients
temperature distribution
milling machines
gradients
Finite element method
linkages
positioning
thermal expansion
roughness
simulation
heat transfer
Thermal gradients
Heat transfer coefficients
computer programs
Temperature distribution
heat

Cite this

Mian, N. S., Fletcher, S., Longstaff, A. P., Myers, A., & Pislaru, C. (2009). Efficient Offline Thermal Modelling for Accurate Assessment of Machine Tool Behaviour. In K. Cheng (Ed.), Laser Metrology and Machine Performance IX - 9th International Conference and Exhibition on Laser Metrology, Machine Tool, CMM and Robotic Performance, LAMDAMAP 2009 (pp. 9-18). euspen.
Mian, N. S. ; Fletcher, S. ; Longstaff, A. P. ; Myers, A. ; Pislaru, C. / Efficient Offline Thermal Modelling for Accurate Assessment of Machine Tool Behaviour. Laser Metrology and Machine Performance IX - 9th International Conference and Exhibition on Laser Metrology, Machine Tool, CMM and Robotic Performance, LAMDAMAP 2009. editor / K. Cheng. euspen, 2009. pp. 9-18
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title = "Efficient Offline Thermal Modelling for Accurate Assessment of Machine Tool Behaviour",
abstract = "Thermal gradients from internal and external heat sources cause instabilities which affect the machine tool positional accuracy. Positioning error results from deformation of the machine structure due to linear thermal expansions of some machine parts combined with the thermal behaviour of associated complex discrete structures producing non linear thermal distortions. Thermal gradients due to internally generated heat and varying environmental conditions pass through structural linkages and mechanical joints where the roughness and form of the contacting surfaces act as resistance to thermal flow and affect the heat transfer coefficients. Measurement of long term thermal behaviour and associated thermal deformations in the machine structure is a time consuming procedure and most often requires machine downtime and is therefore considered a dominant issue for this type of activity, whether for characterisatio n or correction. This paper presents a novel offline technique using Finite Element Analysis (FEA) to simulate the combined effects of the internal and external heat sources on a small vertical milling machine (VMC). Detailed long term experimental testing of the effects of temperature distribution in the machine structure and in-depth heat transfer work to obtain accurate values of heat transfer coefficients across joints is reported. Simplified models have been created offline using FEA software and the evaluated experimental results applied for offline simulation of the thermal behaviour of the machine structure. The FEA simulated results obtained are in close correlation with the obtained experimental results. FEA simulation enables quick and efficient of fline assessments of temperature distribution and displacement in the machine tool structures along with characterisation of the machine under variable environmental conditions. This results in a significant reduction in machine non productive downtime and can provide significantly more thermal data for the creation and validation of robust long term error compensation models.",
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Mian, NS, Fletcher, S, Longstaff, AP, Myers, A & Pislaru, C 2009, Efficient Offline Thermal Modelling for Accurate Assessment of Machine Tool Behaviour. in K Cheng (ed.), Laser Metrology and Machine Performance IX - 9th International Conference and Exhibition on Laser Metrology, Machine Tool, CMM and Robotic Performance, LAMDAMAP 2009. euspen, pp. 9-18.

Efficient Offline Thermal Modelling for Accurate Assessment of Machine Tool Behaviour. / Mian, N. S.; Fletcher, S.; Longstaff, A. P.; Myers, A.; Pislaru, C.

Laser Metrology and Machine Performance IX - 9th International Conference and Exhibition on Laser Metrology, Machine Tool, CMM and Robotic Performance, LAMDAMAP 2009. ed. / K. Cheng. euspen, 2009. p. 9-18.

Research output: Chapter in Book/Report/Conference proceedingConference contribution

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N2 - Thermal gradients from internal and external heat sources cause instabilities which affect the machine tool positional accuracy. Positioning error results from deformation of the machine structure due to linear thermal expansions of some machine parts combined with the thermal behaviour of associated complex discrete structures producing non linear thermal distortions. Thermal gradients due to internally generated heat and varying environmental conditions pass through structural linkages and mechanical joints where the roughness and form of the contacting surfaces act as resistance to thermal flow and affect the heat transfer coefficients. Measurement of long term thermal behaviour and associated thermal deformations in the machine structure is a time consuming procedure and most often requires machine downtime and is therefore considered a dominant issue for this type of activity, whether for characterisatio n or correction. This paper presents a novel offline technique using Finite Element Analysis (FEA) to simulate the combined effects of the internal and external heat sources on a small vertical milling machine (VMC). Detailed long term experimental testing of the effects of temperature distribution in the machine structure and in-depth heat transfer work to obtain accurate values of heat transfer coefficients across joints is reported. Simplified models have been created offline using FEA software and the evaluated experimental results applied for offline simulation of the thermal behaviour of the machine structure. The FEA simulated results obtained are in close correlation with the obtained experimental results. FEA simulation enables quick and efficient of fline assessments of temperature distribution and displacement in the machine tool structures along with characterisation of the machine under variable environmental conditions. This results in a significant reduction in machine non productive downtime and can provide significantly more thermal data for the creation and validation of robust long term error compensation models.

AB - Thermal gradients from internal and external heat sources cause instabilities which affect the machine tool positional accuracy. Positioning error results from deformation of the machine structure due to linear thermal expansions of some machine parts combined with the thermal behaviour of associated complex discrete structures producing non linear thermal distortions. Thermal gradients due to internally generated heat and varying environmental conditions pass through structural linkages and mechanical joints where the roughness and form of the contacting surfaces act as resistance to thermal flow and affect the heat transfer coefficients. Measurement of long term thermal behaviour and associated thermal deformations in the machine structure is a time consuming procedure and most often requires machine downtime and is therefore considered a dominant issue for this type of activity, whether for characterisatio n or correction. This paper presents a novel offline technique using Finite Element Analysis (FEA) to simulate the combined effects of the internal and external heat sources on a small vertical milling machine (VMC). Detailed long term experimental testing of the effects of temperature distribution in the machine structure and in-depth heat transfer work to obtain accurate values of heat transfer coefficients across joints is reported. Simplified models have been created offline using FEA software and the evaluated experimental results applied for offline simulation of the thermal behaviour of the machine structure. The FEA simulated results obtained are in close correlation with the obtained experimental results. FEA simulation enables quick and efficient of fline assessments of temperature distribution and displacement in the machine tool structures along with characterisation of the machine under variable environmental conditions. This results in a significant reduction in machine non productive downtime and can provide significantly more thermal data for the creation and validation of robust long term error compensation models.

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M3 - Conference contribution

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BT - Laser Metrology and Machine Performance IX - 9th International Conference and Exhibition on Laser Metrology, Machine Tool, CMM and Robotic Performance, LAMDAMAP 2009

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PB - euspen

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Mian NS, Fletcher S, Longstaff AP, Myers A, Pislaru C. Efficient Offline Thermal Modelling for Accurate Assessment of Machine Tool Behaviour. In Cheng K, editor, Laser Metrology and Machine Performance IX - 9th International Conference and Exhibition on Laser Metrology, Machine Tool, CMM and Robotic Performance, LAMDAMAP 2009. euspen. 2009. p. 9-18