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Abstract This thesis presents a simulation system which is employed in order to evaluate the static, dynamic, and thermal performance of machine tools. Obtaining such a virtual model could replace many experimental tests that must otherwise be carried out each time the parameters affecting the machine performance are changed. The system is created based on well- defined design considerations, then, it is verified, and applied on some realistic cases. The system evaluates the machine tool performance based on several perspectives namely: static loop stiffness, mode shapes, frequency response function at tool center point, and thermal deformation. Mechanical modeling of mechanical structure and other subsystems of machine tool is achieved, cutting loads are analytically generated, and the heat generation at the hot spots is determined as well. Cutting conditions, cutter and work piece characteristics, category of mechanical structure, supporting webs, position of spindle head are all considered when evaluating the performance of the machine tool in order to provide designers with helpful recommendations in the early design stage. The obtained results from the designed simulation approach provide an evaluation of the behavior of the tool center point in relation to the work piece. Since that behavior will be reflected on the product, these results can be used as criteria for the product accuracy. The designed evaluation system is proved to give a realistic simulation of the performance of machine tools that concerns the behavior of various machine tool elements and the parameters affecting the machining process. |