A milling model with thermal effects including the dynamics of machine and work piece

This paper deals with the development of a new mathematical model that characterizes the structure-process interaction for a complex milling system. The structure is divided into a work piece and a machine part, which are represented by different models. While the machine dynamics is characterized by a standard multi-body system, the work piece is described as a linear thermo-elastic continuum. The coupling of both parts is carried out by an empirical process model permitting an estimate of heat and coupling forces occurring during milling. This work reports the derivation of the governing equations emphasizing the coupling and summarizes the numerical algorithms being applied to solve the coupled equation system. The results of numerical simulations that show the dynamics of the complex thermo-mechanical system are presented at the end