Real-time cutting simulation system of a milling operation for autonomous and intelligent machine tools

The conceptual architecture of autonomous and intelligent machine tools has been proposed not only to generate flexibly the process and operation plan but also to utilize the machine tools and cutting tools' performance while satisfying the requirements of the products and avoiding unexpected machining trouble. In order to realize the autonomous milling, machining strategy such as tool paths and cutting conditions must be decided, not in advance like current NC machining, but in a real-time manner. The objective of this research is to develop a real time machining optimization with machining simulation. Consequently, a cutting simulation system called a virtual machining simulator has been developed for this purpose. This simulator can calculate the changing geometry of the workpiece and estimate the instantaneous cutting force, torque, etc using the physical model. This estimated information enables the system to decide the suitable cutting conditions according to the machinability evaluated. In this paper, the machining status is evaluated and the cutting conditions are modified in real time so that the requirement of the machining operation is satisfied by referring to the physical model. The reliable and safe machining operation is carried out by maintaining the cutting force and torque desired value.