Data Dependent Systems methodology for validation of simulation models illustrated by end-milling

With the availability of modern engineering workstations, it is important to use more realistic models for simulation of machining processes. The purpose of this paper is to illustrate the application of Data Dependent Systems (DDS) methodology in ascertaining how realistic a simulation model is, by comparing its results with real data from an end-milling process. Modal decompositions provided by DDS models from real and simulation data are used to illustrate that the dynamic content of actual end-milling force signals does not match that of the selected simulation model. Specifically, actual force signals have significantly more power at the spindle frequency and more power at the harmonics of the tooth frequency than the simulation model predicts.