Dynamic Analysis of the Dynamill G5 gantry milling machine Using Simulation and Experimental Approaches

This thesis presents an in-depth dynamic analysis of CNC machine tools, specifically focusing on the Dynamill G5 gantry milling machine, through both simulation and experimental approaches. The study begins by establishing a comprehensive Finite Element Model (FEM) in CATIA V5, which simulates the machine's structural dynamics, enabling the calculation of critical dynamic responses such as Frequency Response Functions (FRF) and stability lobe diagrams. Concurrently, Experimental Modal Analysis (EMA) is conducted using impact testing to acquire real-world dynamic data, including modal shapes, resonance frequencies, and damping values. The data from these experimental measurements provide a foundation for validating the simulation model, ensuring its accuracy in predicting the machine’s dynamic behavior under operational forces. The study further correlates the FEM and EMA results, identifying consistencies and discrepancies to enhance the model's reliability. Using the MillingStab software, stability lobes diagrams are computed, which guide the optimization of machining parameters, minimizing chatter and ensuring operational stability. This research provides practical insights into CNC machine tool dynamics, offering theoretical and experimental recommendations that enhance machining precision, stability, and productivity. The combined approach of simulation and experimental validation underpins the development of advanced methodologies for dynamic performance evaluation in CNC machining, contributing to improved design strategies and optimized operational conditions.