Simulation model for quick predictions of workpiece dynamic response in machining

Case studies have shown that the proposed method for a quick simulation of workpiece dynamics in machining allows building an approximate model of the initial FE model using the Padé approximation. The parameters of the approximate model are the element virtual densities, which are then used to eliminate chosen elements based on the material removed during machining. This procedure allows usage of the Padé approximate model to simulate machining of the workpiece with the same clamping used in computation of the Padé approximation. The Padé approximation allows almost a real time computation of the model responses without any need to use the FEA environment. FEA is only needed once to generate the Padé approximate model. The Padé approximation performed on given cases is very close to the results obtained in full FEA and therefore it may serve as a reliable surrogate to a full FEA. The proposed method fulfills the requirements defined in the DynaMill project and can therefore very efficiently serve for quick optimizing the tool path and cutting conditions taking into account the workpiece varying static and dynamic responsse during machining.