The paper discusses the development of an integrated simulation model of the mechanical structure and the control system of a three-axis milling machine for the super-finishing of moulds and dies. This integration encompasses the automatic reduction of a detailed finite element model of the machine tool into a low-order state-space model, appropriate for control system design. It is shown that a multi-stage component mode reduction and synthesis procedure allows a cheap analysis of the machine tool in different spatial configurations. The subsequent development of the motion and vibration control system fully exploits the knowledge of the dynamic behaviour of the machine for all possible tool positions, by a judicious selection of robustness weighting functions in an H control theory framework. The idea of integrating the model of the mechanical structure and of the control system for a simultaneous optimisation of the machine tool performance is essential in the mechatronic design approach.

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