A virtual machine tool, a computer simulation model of the machine motion and cutting process with a level of accuracy and consistency that can replace an accurate machine tool, is one of the critical digital transformation technologies in the manufacturing industry. During the machine development phase, cost and time can be reduced by evaluating machining efficiency and quality through virtual prototyping. In the machine application phase, virtual machine tools can be used to accurately assess the condition of equipment and processes by analyzing actual data combined with simulated data. This paper introduces a virtual machine tool system that can analyze the behavior of an accurate machine tool by integrating physical models of structure, numerical controller, and cutting process. The key features of the virtual machine tool, synchronous machining simulation, machining stability detection, machining error estimation, and part program optimization, were evaluated through various machining tests with a vertical 3-axis milling machine.
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A Review of Intelligent Machining Process in CNC Machine Tool Systems Joo Sung Yoon, Il-ha Park, Dong Yoon Lee International Journal of Precision Engineering and Manufacturing.2025; 26(9): 2243. CrossRef
With the advent of the 4th industrial revolution, advanced digital manufacturing technologies are actively developed to strengthen manufacturing competitiveness. Smart factories require a real-time digital twin including a Cyber-Physical System (CPS) of machines and processes and intelligent technologies based on the CPS. To predict machining quality and optimize machines and processes, it is necessary to analyze the cutting force during machining. Therefore, for real-time digital twin, a fast cutting force simulation model that receives information such as the positions of the feed axes in short time intervals from the CNC and calculates the cutting force until the next information is input is required. This paper proposes a voxel-based fast cutting force simulation in NC milling for real-time digital twin. The proposed simulation model quickly calculates the cutting force by using only information of voxel elements removed by each tool edge without complicated Cutter-Workpiece Engagement (CWE) and chip thickness calculations in previous studies. To verify the performance of the developed simulation, experimental machining was performed and the measured cutting force and simulated cutting force were compared. It was demonstrated that the proposed model can successfully predict the cutting force 3.5 times faster than the actual process.
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Autonomous Mobile Machining and Inspection System Technology for Large-Scale Structures Seung-Kook Ro, Chang-Ju Kim, Dae-Hyun Kim, Sungcheul Lee, Byung-Sub Kim, Jeongnam Kim, Jeong Seok Oh, Gyungho Khim, Seungman Kim, Seongheum Han, Quoc Khanh Nguyen, Jongyoup Shim, Segon Heo International Journal of Precision Engineering and Manufacturing.2025; 26(9): 2345. CrossRef
Among the monitoring technologies in the metal-cutting process, tool wear is the most critical monitoring factor in real machining sites. Extensive studies have been conducted to monitor equipment breakdown in real-time. For example, tool wear prediction studies using cutting force signals and deducting force coefficient values from the cutting process. However, due to many limitations, those wearable monitoring technologies have not been directly adopted in the field. This paper proposes a novel tool wear predictor using the cutting force coefficient with various cutting tools, and its validity evaluates through cutting tests. Tool wear prediction from the cutting force coefficient should conduct in real-time for adoption in real machining sites. Therefore, a real-time calculation algorithm of the cutting force coefficient and a tool wear estimation method proposes, and they compare with actual tool wear in cutting experiments for validation. Validation cutting tests are conducted with carbon steel and titanium, the most commonly used materials in real cutting sites. In future work, validation will be conducted with different materials and cutting tools, considering the application in real machining sites.
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A Review of Intelligent Machining Process in CNC Machine Tool Systems Joo Sung Yoon, Il-ha Park, Dong Yoon Lee International Journal of Precision Engineering and Manufacturing.2025; 26(9): 2243. CrossRef
The kinematic constraints used in a computerized numerical control (CNC) interpolator are one of the main factors determining a machine tool’s machining accuracy. The CNC generates velocity profiles by applying kinematic constraints such as jerk and acceleration. Therefore, changing the kinematic constraints values can adjust the cycle time and cornering error. This study proposes a method to adjust the kinematic constraint values. First, the relationship between CNC kinematic constraints and cornering errors were analyzed. The relationship between the kinematic constraints and the cornering error was expressed as an analytical solution. Kinematic constraint values that satisfy specific cornering error values were selected using the analytical solution of cornering error. Finally, a method was devised to apply the appropriate kinematic constraint values to each machining section within a part program. The analytical solutions for cornering errors and using different machining segments to control cornering errors were verified using tool path generation simulation.
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In this study, the structural integrity of an engine-generator support structure of hybrid drone is verified through finite element (FE) analysis and experimental investigation. From preliminary experiments, critical failures in four columns of the support structure were observed. Due to the repeated cyclic loads induced by the engine-generator operation, the results of the FE simulation pointed out that fatigue failure is the main cause. To improve the structural integrity, the geometric shape and the material of the structural members are modified and changed, and the safety factor is also reviewed using static structural analysis. The possibility of critical resonance is evaluated through FEM-associated modal analysis and a series of vibration tests. As result, it is confirmed that the re-designed support structure was structurally improved with enough safety margin through FE analysis and experimental investigation, and fatigue life by comparing the predicted value and S-N curve of the material used to the support structure was improved.
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The high-frequency electric resistance welding (HF-ERW) process is widely used in the steel pipes production because it can weld at a high speed, has excellent weldability, and attains clean and precise shapes. However, for process improvement, analytic studies on electromagnetic field and temperature distributions, and selection of appropriate process variables are required. In this study, finite element analysis models that can analyze the electromagnetic field distribution and temperature distribution in the HF-ERW of a steel pipe were proposed, in consideration of the characteristics of the process, including electromagnetic phenomena localized to the workpiece surface and fast welding speed. By applying the proposed analysis models, changes in current density, magnetic flux density, generated heat density, and fused width in the pipe could be predicted according to changes in process variables such as the V angle of the strip, the electrode position, and the source voltage. Through comparison with the analysis and the limited-case experiment, the analysis result predicted the actual fused width fairly well, and the validity of the proposed model could be verified.
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Durability evaluations were conducted using polymer electrolyte membrane fuel cells in a marine environment. Deionised water and 3.5 wt% of NaCl solution were supplied to the cathode using an ultrasonic vibrator. Performance and electrochemical impedance spectroscopy of fuel cells were measured to evaluate the electrochemical behaviors. Additionally, long-term stability evaluations of PEMFCs were carried out at 0.65 V for 20 h. Following the experiments, scanning electron microscope analysis was conducted to confirm the presence of NaCl on membrane electrode assembly and micro porous layer of fuel cells.
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SFT, which has a high glass fiber content, is one of the effective methods to replace metal and secure weight reduction and price competitiveness. This study evaluated the effect of glass fiber shape on mechanical properties in injection molding by fabricating SFT with a glass fiber content of 60%. Three types of SFTs were manufactured by adding round glass fibers of Φ7 μm and Φ10 μm and flat glass fibers of 27 × 10 μm. DOE (Design of Experiment) conducts to confirm the change in tensile strength due to changes in significant injection conditions. As a result of the experiment, Φ7 μm SFT and flat SFT have similar tensile strength and Φ10 μm SFT showed the lowest tensile strength value. As for the standard deviation of strength value, the Φ7 μm SFT had the largest standard deviation, and the Φ10 μm SFT showed the slightest change in the injection conditions. In flat SFT, it confirms that the tensile strength increased as the molding temperature increased. The fracture surface observes using SEM. It founds that the tensile strength lowers due to the small glass fiber density and many pullouts at the fracture surface of Φ10 μm with weak strength.
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