Process parallel simulation of workpiece temperatures using sensory workpieces

Abstract Process induced heat causes workpiece shape deviations during machining and may result in rejected parts. As unpredictable processing and boundary conditions cannot be simulated in the process planning phase, a process parallel simulation of the workpiece temperature is required to observe and compensate thermal effects. To parametrize the process parallel simulation model, a parameter identification method for milling operations is developed. With model order reduction (MOR) the computational time is reduced to enable the process parallel simulation. An observer based on a few temperature measurements during machining is designed to reconstruct the non-measurable temperature distribution. A validation proves the methods’ potential.