Design of a 5-Axis Ultraprecision Micro Milling Machine – Ultramill: Part 2: Integrated Dynamic Modelling, Design Optimization and Analysis

Using computer models to predict the dynamic performance of ultraprecision machine tools can help manufacturers substantially reduce the lead time and cost of developing new machines. However the use of electronic drives on such machines is becoming widespread, the machine dynamic performance depends not only upon the mechanical structure and components but also the control system and electronic drives. Bench-top ultraprecision machine tools are highly desirable for micro manufacturing high-accuracy micro mechanical components. However the development is still at the nascent stage and hence lacks standardised guidelines. Part 2 of this two-series paper proposes an integrated approach which permits analysis and optimization of the entire machine dynamic performance at the early design stage. Based on the proposed approach the modelling and simulation process on a novel 5axis bench-top ultraprecision micro milling machine tool – UltraMill is presented. The modelling and simulation cover the dynamics of the machine structure, moving components, control system and the machining process, and are used to predict the entire machine performance of two typical configurations.