• Journal of the Korean Society for Precision Engineering
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• v.32 no.5
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• pp.447-454
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• 2015

Design and application of hardware-in-the-loop simulation (HILS) for design of CNC-controlled machine tool feed drives is discussed. The CNC machine tool is a complex mechatronics system where the complexity results from the software-based controller composed of a variety of functionalities and advanced control algorithms. Therefore, using a real CNC controller in the control simulation has merits considering the efforts and accuracy of the simulation modeling. In this paper challenges in HILS for a CNC controlled feed drive, such as minimization of time delay and transmission error that are caused by discretization of the feed drive model, is elaborated. Using an experimental HILS setup of a machine tool feed drive applications in controller gain selection and CNC diagnostics are presented.

• Journal of the Korean Society for Precision Engineering
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• v.10 no.4
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• pp.94-103
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• 1993

In this work, the imaginary part of the inner modulation transfer function of the cutting dynamics is introduced for tool wear monitoring. Time-series method is utilized to construct the general three dimensional cutting dynamics whose imaginary part of the inner modulation transfer funcition shows the proportionality to tool wear at the natural frequency of the machine tool dynamics. Thus model is reduced to single-input single-output model without altering the proportionality characteristics to tool wear and implemented to the dual computer system in which one computer performs measurement while the other calculates the imaginary part of the inner modulation transfer function of the cutting dynamics by the batch least square method. The values of the imaginary part at the natural requency of the machine tool structure in the cutting direction are compared to the one calculated during machining with a brand new tool to decide the current status of the tool. The experiments shows the relevance of the proposed concept.

• Journal of Mechanical Science and Technology
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• v.15 no.11
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• pp.1482-1489
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• 2001

Thermally-induced errors originating from machine tool errors have received significant attention recently because high speed and precise machining is now the principal trend in manufacturing proce sses using CNC machine tools. Since the thermal error model is generally a function of temperature, the thermal error compensation system contains temperature sensors with the same number of temperature variables. The minimization of the number of variables in the thermal error model can affect the economical efficiency and the possibility of unexpected sensor fault in a error compensation system. This paper presents a thermal error model with minimum number of variables using a fuzzy logic strategy. The proposed method using a fuzzy logic strategy does not require any information about the characteristics of the plant contrary to numerical analysis techniques, but the developed thermal error model guarantees good prediction performance. The proposed modeling method can also be applied to any type of CNC machine tool if a combination of the possible input variables is determined because the error model parameters are only calculated mathematically-based on the number of temperature variables.

• Korean Journal of Computational Design and Engineering
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• v.14 no.1
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• pp.18-24
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• 2009

This paper proposes an analytical method of evaluating the maximum error by modeling the exact tool path for the tool traverse singular region in five-axis machining. It is known that the NC data from the inverse kinematics transformation of 5-axis machining can generate singular positions where incoherent movements of the rotary axes can appear. These lead to unexpected errors and abrupt operations, resulting in scoring on the machined surface. To resolve this problem, previous methods have calculated several tool positions during a singular operation, using inverse kinematics equations to predict tool trajectory and approximate the maximum error. This type of numerical approach, configuring the tool trajectory, requires much computation time to obtain a sufficient number of tool positions in a region. We have derived an analytical equation for the tool trajectory in a singular area by modeling the tool operation into a linear and a nonlinear part that is a general form of the tool trajectory in the singular area and that is suitable for all types of five-axis machine tools. In addition, we have evaluated the maximum tool-path error exactly, using our analytical model. Our algorithm can be used to modify NC data, making the operation smoother and bringing any errors to within tolerance.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.21 no.12
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• pp.2134-2145
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• 1997

We present a framework of an intelligent design system for embodiment design of machine tools which can support efficiently and systematically the machine design by utilizing design knowledge such as objects(part), know-how, public, evaluation, and procedures. The design knowledge of machining center has been accumulated through interview with design experts of machine tool companies. The processes of embodiment design of machining center are established and represented by the IDEF0 model from the field surveys. We also introduce a hybrid knowledge representation so that the system can easily deal with various and complicated design knowledge. The intelligent design system is being developed on the basis of object-oriented programming, and all parts of a design object, machining center, are also classified by the object-oriented modeling.

• Korean Journal of Computational Design and Engineering
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• v.3 no.4
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• pp.293-303
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• 1998

The objective of this study is to develop a PC level freeform surface modeling system which explicitly represents information of part geometry. Surface modeler uses nonuniform rational B-spline (NURBS) function with nonuniform knot vector for the flexible modeling work. The results of this study are as follows. 1) By implementation surface modeler through applying representation scheme proposed to represent free-form surface explicity, the technical foundation to develop free-from surface modeling system using parametric method. 2) Besides the role to model geometric shape of a surface, geometric modeler is developed to model arbitrary geometric shape. By doing this, the availability of the modeling system is improved. Geometric modeler can be utilized application fields such as collision test of tool and fixture, and tool path generation for NC machine tool.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2002.10a
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• pp.365-369
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• 2002

This paper introduces that the machine tools's feed system optimizes by modeling for simulation and adjusting drive control parameter. The first method is frequency response of speed loop with design parameter by use of MATLAB application, in order that other axis can do equal to bandwidth. The second meted uses various sensor for analyzing machine tools's structure and adjustes jirk limitter.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1997.10a
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• pp.207-212
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• 1997

The purpose of this study is the development of CAM system which can cut and measure any shape by machining center and coordinate measuring machine. The overall goal of the CAM system is to achieve the CNC machining, from digitizing through to final cutting. The hardware of the system comprises PC and machining center, CMM. There are three steps in the CNC machining, (1) workpiece measuring on the CMM, (2) geometric modeling by the CAD system, (3) NC commands generation by the tool path compensated for tool nose radius. It is developed a software package, with which can conduct a micro CAM system in the PC without economical burden.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.5
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• pp.19-24
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• 2002

• Journal of the Korean Society for Precision Engineering
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• v.26 no.6
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• pp.68-73
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• 2009

One of the traditional optical methods to monitor a tool is a CCD sensor-based vision system which captures an aspect of the tool in real time. In the case using the CCD sensor, specific lens-modules are necessary to monitor the tool with higher resolution than its pixel size, and a microprocessor is required to attain desired data from captured images. Thus theses additional devices make the entire measurement system complex. Another method is to use a pair of an optical source and a detector per measuring axis. Since the method is based on the intensity modulation, the structure of the measurement system is simper than the CCD sensor-based vision system. However, in the case measuring the three dimensional position of the tool, it is difficult to apply to micro machine-tools because there may not be space to integrate three pairs of an optical source and a detector. In this paper, in order to develop a tool-origin measurement system which is employed in micro machine-tools, the improved method to measure a tool origin in x, y and z axes is introduced. The method is based on the intensity modulation and employs one pair of an optical source radiating divergent beams and a quadrant photodiode to detect a three dimensional position of the tool. This paper presents the measurement models of the proposed tool-origin sensor. The models were verified experimentally The verification results show that the proposed method is possible and the induced models are available for design.