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This paper presents the 3D virtual model of the numerical control machine Modustar 100, in terms of machine elements. This is a CNC machine of modular construction, all components allowing the assembly in various configurations. The paper focused on the design of the subassemblies specific to the axes numerically controlled by means of CATIA v5, which contained different drive kinematic chains of different translation modules that ensures translation on X, Y and Z axis. Machine tool development for high speed and highly precise cutting demands employment of advanced simulation techniques witch it reflect on cost of total development of the machine.

The primary goal of this study is to develop a wearable system for providing CNC machine operators with visual and tactile perception of triaxial cutting forces, thereby assisting operators in industrial environments to enhance work efficiency and prevent mechanical failures. To achieve this goal, we successfully integrated a virtual machining tool simulator with the remote-control wearable system (RCWS). Using the ‘King Path’ milling parameters, we employed the simulation software developed by the AIM-HI team to calculate static and dynamic cutting forces, converting this data into vibrational commands for the RCWS to generate corresponding tactile feedback. Furthermore, we conducted extensive experiments, testing various data conversion methods, including three sampling techniques and two data compression strategies, aiming to provide accurate tactile feedback related to cutting forces under different operating conditions.

This work aims to generate the digital documentation related to a number of manufacturing processes on different machine tools. The project is developed with the contribution of engineering students doing their final thesis within this field. Different machine tools and machining and incremental forming processes have been virtualized by using the CAD/CAM software CATIA V5. Some of the modeled parts were finally manufactured after checking and post-processing the NC code. Digital documentation is developed on different formats (e.g. photographs, videos, images and simulations) in order to be used as a teaching complement.

Virtual machine tools have been used widely for simulating designs in computer environments to determine optimal design parameters without the need for manufacturing prototypes. Machine tools include different multiple configurations that are designed to be suitable for the differing requirements of production. To date, studies on dynamic analysis have been limited to a few-axis machine tools of a specific configuration, such as a 3-axis milling machine or a 4-axis grinding machine. Here, we propose a novel method to focus on the dynamic analyses of multi-axis machines with differing multiple configurations. The motion equations for multiple degrees of freedom of linear and rotary axes are established by a Lagrange energy method, equilibrium equations, and Newton’s second law. This technique formulates the motion equations for each axis, and then further develops them for a multi-axis machine through a combination process and a transformation matrix. The library includes five dynamic model components, built to simulate 1236 different configurations of a machine tool. A dynamic analysis was applied to a control system to simulate the control signals of a virtual machine, which include stepped, ramped, curved, sinusoidal, and circular responses, and frequency response functions. The simulated and experimental results demonstrated that the method has high accuracy and reliability for one-, two-, and four-axis machine tools. Thus, this method can simulate the dynamic analyses of multi-axis machines and different multi-configurations without the need to build a specific configuration for each machine. It is recommended for selecting optimal motors, design parameters, and control parameters of the multiple configurations in a machine tool.

This paper proposes a novel, fast, and automatic modeling method to build a virtual model with minimum degrees of freedom (DOFs) without the need for FE models or human judgment. The proposed program uses the iterative closest point (ICP) algorithm to analyze the mode shape vector of structural dynamic characteristics to define the position and DOFs of the joints between structural components. After the multi-body dynamics model was developed in software, it was converted into an SSM to connect the servo loop model. Then, the mechatronic integration analysis was performed to verify the dynamic characteristics of the tool center point (TCP) and the workbench in the experiment and simulation. The model created by the proposed identification process has a small DOF and can accurately simulate the dynamic characteristics of a machine. This model can be used for dynamic testing and control strategy development in mechatronic integration.

Building a virtual machine tool model not only is advantageous for collision prevention and process planning in machining manufacturing operations, but also is a didactic resource for training users about operating physical machine tools. A generic procedure for developing a numerically controlled virtual machine tool in a standard PLM (product lifecycle management) platform is given. The procedure was applied to model the Hartford SMC5 machining center using the software Siemens NX 9. The first step in the process simplifies the machining center into a hierarchy of components using kinematic chains; the second step assigns information regarding motion to each machine component; the final step controls the movements of the machine components by means of a virtual controller and a postprocessor. Once complete, a validation procedure of the model is provided by modeling, simulating, and executing the manufacturing process of a selected workpiece with complex surfaces.

In order to respond to market rapidly, save design time, reduce the cost and particularly design the machine in a predictable and reliable manner, an approach based on the integration of virtual machine tool and workpiece material removal mechanism is proposed in this article for the investigation of centerless grinding process, the prediction of workpiece roundness generation and the evaluation of dynamic characteristics of grinding system. In this approach the machine structure model is firstly presented by incorporating the kinematic relationship of the feed drive system and the material dynamic parameters of the grinding system. Then the virtual machine tool model is built by the combination of the machine mechanical structure and the control loop. Finally the virtual centerless grinding is realized by integrating the virtual machine and the workpiece material removal mechanism through their coupled surface regeneration mechanism. The comparison of the experimental and theoretical results demonstrates that this virtual centerless grinding approach can investigate the workpiece roundness generation accurately.

A key factor for realising an Internet-based virtual manufacturing system (VMS) and virtual enterprise (VE) is how to represent the manufacturing elements and process mechanics precisely and effectively. This paper presents methods to represent the motion paths and operation of CNC machine tools on the Web. The method is composed of: 1. Geometrical modelling of the machine tools. 2. Kinematic modelling of the movements of machine tools. 3. Representation of the developed model in the internet infrastructure. 4. Development of a prototype Web-based virtual machine tools (WVMT). WVMT is available on the internet URL http://wvmt. postech. ac.kr, by which the client can interactively operate CNC machine tools, and verify the part program via graphic simulation.

Wire electrical discharge machining (WEDM) uses a metallic thin wire to cut a programmed profile with high strength having sharp edges such as extrusion dies and blanking punches. However, the cost of purchasing and maintaining of WEDM equipment is very high for both the industry and general education institutions. Therefore, there are potential demands to reduce the expensive machine operation training cost, provide off-line collision-free simulation verification of the tool path, and examine the correctness of the programmed wire cutting NC codes. This paper presents the development of a virtual reality-based WEDM full machine simulation system which can emulate major functions of a real controller related to operation training and education. These functions include the tool path simulation, NC program interpretation and processing, kinematics of the machine mechanism, workpiece origin setting, etc. To demonstrate the developed system and illustrate the adopted method, the system capability is explained and shown in this paper. The research result can be used as a cost-effective interactive 3D digital tutoring system that has the benefits of improving on the inefficient, dangerous, and costly drawbacks in traditional learning and training for operating the real WEDM machine.

The application of traditional three-axis milling machine center is very popular and the related application technology is also much matured resulting in mechanical components to be machined with good quality. Machine tool has therefore become an inevitable facility in precision manufacturing. Furthermore, the pursuit of higher precision machining has thus demanding five-axis machine tool to be adopted owing to its flexibility and capability in machining more precise mechanical components in shorter time. However, one of the key factors for the popularity in smooth introduction of five-axis machine tool would be based on a very user friendly learning and teaching environment. This is partly because two more rotational axes in a five-axis machine tool could generate very complex toolpath movement that is out of the imagination of a general operator. Furthermore, the price of an industrial five-axis machine tool is not normally affordable by an educational institute; to the worse, the maintenance cost is also very high. There is very high risk for a novice to collide during the learning process and this will generally cause big worry of a teacher. This paper aims for the development of a virtual machining center simulation system with switchable modular components to ease the learning process in getting acquainted with a five-axis machine tool. A five-axis machine tool consists generally of two modules: (1) CNC controller and Operation panel, and (2) machine tool hardware. The developed system will provide the novice with four CNC controller with operation human machine interface (HMI), and three typical types of five-axis machine tool, Head-Head (HH), Head-Table (HT), and Table-Table (TT), are also supported. The developed modularized and switchable machining center simulation system has been successfully developed and is very helpful to both learner and teacher