Modelling and simulation of machining centre for high speed milling

The main characteristic of High-Speed Milling (HSM) is the possibility of increasing material removal rates, decreasing cutting time and at the same time enhancing machining accuracy and workpiece surface quality. It is therefore now one of the most promising and advanced manufacturing technologies. However, this technology requires a sophisticated design of the whole machine tool, like the dynamic study and optimisation of the feed drives and of the mechanical structures: base, uprights, cross slides. Through the development of a “virtual” machine using appropriate software models, it is possible and convenient to verify the effectiveness of alternative project solutions aimed at making both the bandwidth of each control loop and the natural frequencies of the structure as high as possible. As already known, these dynamic parameters determine the optimisation of the CNC and drive functions, thus maximizing the metal removal rate. The paper presents some intermediate results of a long range research developed by the authors, with the technical and financial support of Breton spa, an Italian company which produces five axes machining centres for HSM. The aim of the research is to deliver advanced project tools to Breton, both to improve the performances of the current machines and for the design optimisation of similar future machine tools.