Machine structure simulation using FEA and optimised thermal parameters

Continuous usage of machine tools during manufacturing processes causes heat generation in the moving elements, resulting in distortion of the machine tool structure. Simulation of this thermal behaviour can be a powerful tool for supporting the design process and predicting errors. Determining accurate heat transfer parameters is needed to improve the prediction accuracy of the physical thermal models. First, the energy balance technique was used to calculate the parameters empirically. Due to uncertainties in the boundary conditions for this technique, an additional novel 2D optimisation technique based on thermal imaging data was used to calibrate the calculated parameters. The effectiveness of the technique was proved using FEA models of the machine. Good correlation of up to 80 % was achieved between simulated thermal characteristics and the experimental data.