Bretschneider, J. and Menzel, T.

Development Report:

Virtual Optimization of Machine Tools and Production Processes

Jochen Bretschneider and Thomas Menzel
Siemens AG, A&D MC MT P
Frauenauracher Strasse 80, 91056 Erlangen / Germany
[Received February 28, 2007; accepted June 1, 2007]

Faster development of innovative machine tools,

shorter processing times, improved surface quality of
workpieces, higher machine productivity these are
just a few of the wishes and demands of machine manufacturers and end-users. Time-to-market is decisive;
in some industries, six months too late on the market
can already be decisive in losing the race for market
leadership. The key to success lies in virtual techniques. These are an extremely cost-effective way to
increase productivity in all phases of the machine tools
life cycle. Siemens AG, the leading provider for control and drive technology, sees itself as a partner for
the whole machine tool industry and offers four phases
of simulation support which cover the entire life cycle of a machine: Mechatronic Support for simulation
for machine development, Machine Simulator for supporting commissioning, Virtual Production for the optimization of production and, finally, Virtual NC Kernel (VNCK) for the testing of NC part programs at the
end-user.

Keywords: machine tool, mechatronic, simulation, development

1. Introduction
Manufacturers of machine tools have come under increasing pressure to introduce their innovative machines
into the market at ever shorter intervals and at ever lower
costs. In addition to these market realities, user demands
for high precision, dynamic and flexible machines with
low life-cycle costs continue to increase. One of the keys
to success for machine manufacturers lies in the area of
machine and machining simulation. Simulation has come
to be regarded as an extremely cost-effective approach to
increasing productivity in all phases of a machine tools
life cycle.
In fulfilling its role as a partner to machine manufacturers and users, Siemens offers four phases of simulation support that encompass the entire life cycle of a machine (see Fig. 1). This phase-based simulation support
includes the innovative services Mechatronic Support and
Virtual Production and the products Sinumerik Machine
Simulator and Virtual NC Kernel.

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Fig. 1. Simulation activities at Siemens for machine manufacturers and users.

2. Mechatronic Support
Mechatronic Support involves the simulated design of
a machine to be developed in the form of a virtual mechatronic machine. The machines properties can be tested,
modified, and optimized in the simulation before the machine is actually built. This can even make the timeconsuming and costly construction of a prototype entirely
superfluous. The virtual mechatronic machine consists of
a dynamic machine model (e.g. a FE model), an electronic
control and drive system and a machining model for the
milling technology. The virtual mechatronic machine allows to analyze and to enhance the essential performance
specifications of a new machine already in simulation.
As a service within the scope of Mechatronics Support,
the corresponding virtual mechatronic machine is created
for the customer machine to be developed (see Fig. 2). To
do so, the machine manufacturer provides Siemens with
the CAD data of the machine. Ideally this is done in the
design phase or at an early stage in the construction so
that construction variants can be verified at very little expense. This enables a machine concept to be optimally
utilized. All analyses that are normally only possible on
a physical prototype of a new machine tool are now performed on the virtual mechatronic machine on a PC.
Simulation with the virtual mechatronic machine can
be used to analyze and improve the main performance parameters that are expected with the new machine, for exInt. J. of Automation Technology Vol.1 No.2, 2007

Virtual Optimization of Machine Tools and Production Processes

NC Part Program

Validate already in Simulation:

Maximum Dynamic of Machine Tool (kv and Jerk)
Resonance Frequencies f 0 / Dynamic Stiffness
Influence of Machine Placement and Foundation
Virtual Milling of Workpieces (Time and Quality)
Fix Weak Points in Machine Concept and overcome it

CNC
Simulation

Drives
Simulation

Mechanics
Simulation

Motion Control
motion control
Interpolation

Simulation

Machining
Simulation

Motors
Servo-Drive
Elements

Position Control
Speed Control
controllers
Current Control

Interpretation
Preparation
compressor

Measurement

4 Pm

N10 G0 Z20
N20 X-23.883 Y-1.858
N30 Z11.298
N40 G1 Z6.298 F5000
N50 G1 Y-1.865 Z5.76
N60 G1 X-23.875 Z5.61

Surface
fineQuality
interpolator

Encoder
Mechanics
drives +
Foundation
mechanics

+ interpolator

Fine
fineInterpolation
interpolator

Measurement

Finite-Ele
ment-M od
el
Siemens
M echatron build up by
ic Suppor
t

Simulation

Fig. 2. Virtual mechatronic machine.

Measurement

Simulation

(with Accelerometer
mounted at TCP*)

Fig. 4. Positioning response of the Y axis measured at the

TCP. Top: soft isolation pads. Bottom: hard isolation pads.

Axial
Axial Stiffness:
Stiffness: 50
50 Hz
Hz
Bode Diagram

A:F1 DJOM(FRES2
X:98
-50
dB

Hz

Y:-64.866 dB

Machine
10
Machine Base:
Base:
10 Hz
Hz
20

From: OUT

Magnitude (dB)

dB Mag

10
dB
/div

-150
dB
1Hz
B:F1 DJOM(FRES2
X:98
180
deg

To: Y(1)

0
-20
-40

Slide
Slide Tilting:
Tilting: 90
90 Hz
Hz

-60

Hz

AVG: 10

Y:-68.789 deg

400Hz

-80
0

Phase (deg)
To: Y(1)

-180

Phase

36
deg
/div

-360

-540

-180
deg
1Hz

AVG: 10

400Hz

-720

10

10

10
Frequency (Hz)

* Tool Center Point

Fig. 3. Frequency response of the Y axis measured between

the velocity of the motor and the Tool Center Point.

ample under the following aspects:

Maximum axis jerk (relevant for machining time)

Positioning response
Control response / disturbance response
Possible controller gains
Static stiffness
Dynamic stiffness (compliance frequency responses)
Circularity test
Analysis of the relevant natural oscillation forms
Influence of the machine mounting and the machine
bed
Influence of the measurement system connection
Chatter forecast for milling (determination of the
cutting depth)
Machining times for a specific acceptance part or
Machining quality.

As an example, Fig. 3 shows the frequency response of

the Y axis, measured between the velocity of the motor
and the tool center point (TCP) of a milling machine
after the machine tool has been built up. Simulation and
Int. J. of Automation Technology Vol.1 No.2, 2007

Fig. 5. CNC connected with Machine Simulator at PC for

virtual commissioning.
X100.5 Y300
X33.1 Y15.8
X5.88 Z100
....

NC User Program

Einfache
Steuerungsnachbildung
Virtual NCK
of SINUMERIK
NC Axis Positions

Third-Party Product of
an Independent
System House
e.g.:

Simulation System (Collision,Material Removal)

CGTech

UGS

Tecnomatix

Source:
Unigraphics Solutions GmbH

Fig. 6. Simulation with Virtual NC Kernel.

measurement show a high level of conformity in amplitude and phase. The mechatronic simulation model can
be used to find the places where natural oscillations occur in the machine. This provides valuable information to
help improve the construction of the machine.
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