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This paper presents an integrated simulation system that is employed in order to evaluate the static and dynamic performance of a milling machine. The paper discusses the design consideration of the evaluation system, creates the system based on finite element technique, applies it to a case study, and discusses the results. Obtaining such a reliable model could replace many experimental tests that must otherwise be carried out each time the parameters affecting cutting conditions are changed. Modeling and meshing of various machine elements including the mechanical structure are carried out, contacts between each adjacent elements are defined, load components generated from machining process are modeled, and finally the static and dynamic performance of the entire machine is evaluated. The machine performance is identified in terms of static loop stiffness in both x and y directions, mode shapes, and frequency response function at tool center point.

Simulation approach to study the behavior of a milling machine''s structure during end milling operation