Clamping Modeling in Automotive Flexible Workpieces Machining

Abstract Predictive dynamic simulations of virtual machining rely on accurate representation of eigenmodes and damping factors. Historically, the modeling of flexible workpieces requires experimental updating of general modal properties, especially due to a simplified definition of fixtures. In the present work a substructuring-based approach for a virtual machining simulation is developed. It is demonstrated on a vibration-prone boring of a thin-walled automotive workpiece. Fixture-affected zones are modeled via MacNeal-type approach. This enables for addressing the influence of clamping in the mechanical modeling of dynamics, and for creating specific models of typical fixture configuration. During simulation vibrations occur on similar frequencies to those observed on real machining. Resulting surface defects follow alike patterns in simulation and experiment.