A digital machining system is a core subsystem of a virtual machining system at the lowest level, and it provides physical attributes of both the machining process and machine tool to the upper application level. A digital machining system based on mechanistic models is developed. An expandable general base model is built in the system and the interfaces for extending to upper level models are provided for easy integration. The system consists of many integrative dynamic machining process simulation models including milling, turning, boring and grinding. The development of the digital machining system is completed by integrating a spindle analysis model through a modular interface using modal superposition methods. The digital machining system is evaluated in aspects of determining spindle related machining process constraints, predicting spindle condition-dependent chatter boundaries and selecting cutting tools.
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