3rd International Conference on Thermal Issues in Machine Tools (ICTIMT2023)

Description

This open access conference proceedings contains all the papers presented at the ICTIMT 2023, the 3rd International Conference on Thermal Issues in Machine Tools. The event takes place in Dresden, the capital of Saxony, from March 21-23 2023. The conference is organized by the Chair of Machine Tools Development and Adaptive Controls of the Technische Universität Dresden. Presentation of CIRP Preface Organization Contents Thermal Error Compensation and Correction Development of Thermal Displacement Prediction Model and Thermal Deformation Measurement Methods 1 Introduction 2 Thermal Displacement Prediction by Deep-Learning 2.1 Convolutional Neural Network (CNN) 2.2 Thermal Sensitivity 2.3 The Prediction Results 3 Thermal Deformation Measurement on a Two-Dimensional Trajectory 3.1 Principle of Error Estimation 3.2 Experimental Results 4 Vision-Based Machine Accuracy Measurement 4.1 Displacement Measurement Using Vision Camera 4.2 Accuracy Measurement Using Vision Camera 4.3 Two-Dimensional Thermal Displacement Measurement Under the Ambient Temperature Change 5 Conclusion References Thermal Compensation of Sudden Working Space Condition Changes in Swiss-Type Lathe Machining 1 Introduction 2 Methodology of Thermal Error Compensation 2.1 Empirical Model Decomposition 2.2 Autoregressive Model with Exogenous Inputs (ARX) 2.3 Random Forest Regression (RFR) 2.4 Stacked ARX-RFR Model for Thermal Compensation 3 Experimental Setup 3.1 Machine Tool and Measurement Equipment 3.2 Model Calibration Phase 3.3 Thermal Test Piece 4 Results 5 Conclusion References Hybrid Thermal Error Compensation Combining Integrated Deformation Sensor and Regression Analysis Based Models for Complex Machine Tool Designs 1 Introduction: Motivation and State of the Art 2 FE Model of the Demonstrator DMU 80 eVo 3 Characteristic Diagram Based Compensation 4 Integrated Deformation Sensors 4.1 Description of the IDS 4.2 Experience Based Sensor Placement 4.3 Mathematical Sensor Placement Using an FE Model 5 Validation 6 Summary and Outlook References Thermal Error Compensation Models Utilizing the Power Consumption of Machine Tools 1 Introduction 2 Experimental Set up 2.1 Analyzed Machine Tool 2.2 Power Intake Measurement 2.3 Temperature Measurement 2.4 Experimental Load Case 3 ARX Compensation Model 3.1 Temperatures and Power Intake as Model Inputs 3.2 Temperatures as Model Inputs 3.3 Power Intake and the Environmental Temperature as Model Inputs 3.4 Power Intake as Model Inputs 3.5 Comparison of Input Sets Using the Volumetric Error 4 Conclusion and Outlook References An Indicative Model Considering Part of the Thermo-Mechanical Behaviour of a Large Grinding Machine 1 Introduction 2 Experimental Setup and Conditions 3 Thermal Error Analyses, Model Developments and Verification 3.1 Modeling Approach and Efficiency Evaluation Method 3.2 Linearity Analyses of Thermo-Mechanical Behaviour 3.3 Indicative Model of MT Thermal Behaviour with Predictive Functionality 3.4 Upgrade of Indicative Model to Compensate for Thermal Errors 4 Discussion of Results and Conclusions References Adaptive Thermal Model for Structure Model Based Correction 1 Introduction 2 Thermo-Elastic Model 2.1 Fundamentals 2.2 Modeling Conception 2.3 Modeling Procedure 3 Parameter Update 4 Trusted Execution Environment 5 Application at Demonstrator Machine 5.1 Model of the Demonstrator Machine 5.2 Parameter Update of Friction Model of Profile Rail Guides 5.3 Performance in Trusted Execution Environment 6 Summary and Outlook References Adaptive Thermal Error Compensation Model of a Horizontal Machining Centre 1 Introduction 2 Thermal Error Experiments 3 Thermal Error Model for a Horizontal Machining Centre 3.1 Identification of the Compensation Model 3.2 Verification Tests Results 4 Adaptive Compensation Model 4.1 Principle of Model Adaptation 4.2 Adaptive Compensation Results 5 Conclusions References Analysing the Impact of Process Dependent Thermal Loads on the Prediction Accuracy of Thermal Effects in Machine Tool Components 1 Introduction 2 Research Overview 3 Finite Element Model 3.1 General Procedure of Thermal Error Estimation 3.2 FE Model Creation 3.3 Automated Optimization of FEM Parameters 4 Obtain Manufacturing Task Characteristic Thermal Loads 4.1 Reference Task for Realistic Load Scenario 4.2 Task Characteristic Power Loss Estimation 4.3 Transformation of Thermal Loads 5 Application and Evaluation of Dynamic Thermal Loads in FEM 5.1 Dynamic Thermal Load Application to Machine Basis 5.2 Dynamic Thermal Load Application in FEM 5.3 Comparison and Evaluation of Measured and Simulated Behaviour 6 Conclusion and Outlook References Process Parallel Models A Data-Based Model of the Thermo-Elastic TCP Error Using the Encoder Difference and Neural Networks 1 Introduction 2 Encoder Difference 3 Methods 3.1 Measurement of Model Inputs and Model Outputs 3.2 Artificial Neural Networks 3.3 Machine Loads 4 Results 4.1 Structural Deformation Close to the Machine Axes 4.2 First Load Case 4.3 Second Load Case 5 Conclusion and Further Work References Model Order Reduction Strategies for the Computation of Compact Machine Tool Models*-12pt 1 Introduction 2 Modeling of Machine Tools 2.1 System-Theoretic Approach 2.2 Efficient Modeling of Time-Varying Thermal Couplings 3 Model Order Reduction for Machine Tools 3.1 Intrusive MOR with Balanced Truncation 3.2 Non-intrusive MOR with the Loewner Framework 4 Numerical Experiments 5 Conclusion References Simulation of Thermoelastic Behavior of Technical Systems with Relatively Moving Parts - Modeling Process, Part Coupling Approaches and Application to Machine Tools*-12pt 1 Introduction 2 Theoretical Background 3 Modeling and Simulation Framework 3.1 Concept 3.2 Coupled Problem Combiner 3.3 CRC/TR96 - Realized Simulation Framework 4 Example Machine Tool Model 4.1 Base Model 4.2 Moving Contacts 4.3 Simulation Results 5 Conclusion and Outlook References Thermal Modal Analysis for Volumetric Error Characterization 1 Introduction 2 Modelling 2.1 Thermo-Elastic Model 2.2 Thermal Modal Analysis 3 Volumetric Thermo-Elastic Modal Analysis 3.1 Machine Finite Element Model 3.2 Volumetric Thermo-Elastic Modal Analysis 4 Results and Analysis 5 Conclusions and Future Steps References Development of a System for the Evaluation and Recommendation of Solution Methods for Thermally Induced Errors on Machine Tools 1 Introduction 2 Methodology 3 Development of a Documentation and Evaluation System 4 Discussion 5 Conclusion References Sensor Integration Smart Pressure Film Sensor for Machine Tool Optimization and Characterization of the Dynamic Pressure Field on Machine Surfaces 1 Introduction 2 State of the Art 2.1 Pressure, Temperature and Flow Sensors 2.2 Shape Memory Alloy Thin Film Sensors 3 Methods 3.1 Use in Machine Tools 3.2 Design and Manufacture of the Flow Sensors 3.3 Experimental Set-Up 4 Results and Discussion 5 Summary References Thermally Induced Clamping Force Deviations in a Sensory Chuck for Thin-Walled Workpieces 1 Introduction 2 Sensory Chuck for Thin-Walled Workpieces 2.1 Sensory Chuck Design 2.2 Thermal Influences on the Actuation Force 3 Compensation of Thermally Induced Clamping Force Deviations 3.1 Clamping Force Adjustments with the Sensing Chuck Prototype 3.2 Compensation of Clamping Force Errors 4 Conclusion References Components Improving the Thermal Behavior of High-Speed Spindles Through the Use of an Active Controlled Heat Pipe System 1 Introduction 2 Concept Design 3 Design of the Experimental Spindle 4 Experimental Setup 5 Results and Discussion 5.1 Responsiveness of the Spindle System to Changes in Heating and Cooling Capacity 5.2 Control of Temperature and Displacement with On-Off Controllers 6 Conclusions and Ongoing Research References Thermal Growth of Motor Spindle Units 1 Causes for Thermal Growth 2 Prediction Methods 2.1 Analytical Equation Method 2.2 Function Block Method 3 Verification of the Simulation by Test Bench Results 4 Thermal Stiffness Strategy 5 Summary and Outlook References Thermal Modeling Challenges of High-Speed Motorized Spindles 1 Introduction 2 General Approach 3 Boundary Conditions for High-Speed Motorized Spindles 3.1 Heat Transfer 3.2 Heat Sinks 3.3 Heat Sources 3.4 Solid Motion Effects 4 Spindle Model and Validation 4.1 Boundary Condition Application to the Simulation Model 4.2 Test Bench and Model Validation 5 Spindle Power Loss Observation 6 Conclusion and Outlook References Design and Materials Experimental Investigation of Passive Thermal Error Compensation Approach for Machine Tools 1 Introduction 2 Compensation Method and Scenario 2.1 Experimental Machine MAX 2.2 Compensation Approach 2.3 Design of Compensation Components 3 Experimental Investigations 3.1 Experimental Set-Up 3.2 Experimental Procedure 4 Experimental Results 5 Discussion 6 Summary References Determination of the Thermal Properties of Pre-stressed Fiber-Reinforced Polymer Concrete 1 Introduction 2 Material-Specific Structure of the Samples 3 Behaviour Under Load at Different Sample Temperatures 4 Conclusion References Tools and Processes Simulation of cBN Grain Wear During Single Grain Engagement Considering Cleavage Planes 1 Introduction 2 State of the Art 3 Experimental Investigations 4 Development of a Simulation Model for the Wear Mechanisms of cBN Grains Considering the Cleavage Planes 4.1 Model Setup 5 Results and Discussion 6 Conclusion References Development of a Tool Temperature Simulation During Side Milling 1 Introduction 2 Overview Workflow 3 Tool Geometry, Mechanical and Thermal Modeling 4 Results 5 Conclusion References Three-Dimensional Modeling of Thermomechanical Tool Loads During Milling Using the Coupled Eulerian-Lagrangian Formulation 1 Introduction 1.1 State of the Art of FEM-Based Cutting Simulation 2 Experimental Procedure 2.1 Experimental Set-Up of Side Milling 2.2 Workpiece Material and Cutting Tool 3 Model Setup of Side Milling 4 Results and Discussion of Simulations and Experiments 5 Conclusion and Outlook References Model Verification Definition of a Non-contact Induction Heating of a Cutting Tool as a Substitute for the Process Heat for the Verification of a Thermal Simulation Model 1 Introduction 2 Induction Heating and Design Boundary Conditions 3 Determination of Heating Power 3.1 Electromagnetic Simulation and Verification of Heating Power 3.2 Simulation of the Heating Power of an End Mill Tool 4 Thermal Simulation 5 Summary References Measuring Thermally Induced Tool Center Point Displacements on Milling Machines Using a Test Workpiece 1 Introduction 2 Experimental Setup and Methods 2.1 Test Work Piece (TWP) 2.2 Machine Tool DMU 80 2.3 Test Setup 2.4 Test Execution 2.5 Experiment Evaluation 3 Measured TCP Errors Due to Thermal Influences 3.1 Determined TCP Error Values 3.2 Comparison of the Deviation in the Determined TCP Error Values for TWP and Measuring Probe Measurements 4 Discussion 5 Conclusion References Author Index