Abstract

Technical problems in mechanical engineering are routinely solved with simulation software. However, correct, realistic statements represent a major challenge [1]. With higher complexity, the influencing factors increase so that the economic effort of the simulation rises. One of these complex issues is the reliable design of machine tools for large-scale production. In the simulative design, the structural and process dynamic properties must be taken into account to ensure process stability. This poses a challenge for small- and medium-sized machine tool manufacturers regarding their design at large-scale production. The configuration-dependent interaction of machine tool and process excitation is related to great effort and thus usually disregarded. If machine tools are designed with high safety factors due to the unknown interaction, individual components or the entire machine tool is oversized. This can lead to higher production costs without ensuring process stability. A novel offer for machine tool manufacturers is presented. The aim is to ensure high process reliability with high machine tool productivity and thus to minimize costs for machine tool manufacturers and customers. A dexel-based process simulation is presented, carried out and validated with experiments using the large-scale production process of ball hub milling.