As the global manufacturing industry moves toward carbon neutrality, improving energy efficiency of machine tools has become essential. Although machine tools contribute significantly to industrial energy consumption, systematic methods for evaluating their energy consumption remain insufficient. To address this issue, this study developed an energy consumption evaluation system based on ISO 14955, the international standard for machine tool energy efficiency. The proposed system enabled a detailed analysis of energy usage patterns in different operating states, identifying key areas for energy reduction. The developed system could measure energy consumption of individual machine tool components in various operating states using power meters and automatically generates reports. This allows users to identify which components and operating states consume the most energy. We tested and validated this system on three different machine tools and analyzed strategies for reducing energy consumption. The developed evaluation system can help machine tool manufacturers integrate it into their equipment, develop energy-efficient technologies, and contribute to sustainable manufacturing.

This paper presents the development of a design optimization module for achieving the best performance of hydrostatic bearings. The design optimization module consists of two components: a bearing performance analysis module and an optimization module that utilizes optimization algorithms. Widely recognized global search methods, genetic algorithm (GA), and particle swarm optimization (PSO) algorithm, were employed as the optimization algorithms. The design optimization problem was defined for hydrostatic bearings. Optimization design processes were carried out to improve load capacity, stiffness, and flow rate. Subsequent experimental validation was conducted through the fabrication of a practical experimental setup. The design optimization model demonstrated superior performance compared to the initial model while satisfying design conditions and constraints. This confirms the practical applicability of the design optimization module developed in this study.

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.

This paper proposes a cycle time estimation algorithm of a CNC machine tool, using a block overlap based tool path generation algorithm. Velocity profile generation algorithm of CNC interpolator is proposed to compute the cycle time of the G-Code block. Because the CNC blends adjacent velocity profiles to reduce the cycle time and smooth the tool path, the cycle time is adjusted considering the block overlap. The in-position time of rapid traverse is compensated to improve the cycle time estimation accuracy. The simulation model was designed to estimate the cycle time of the CNC machine tool. A three-axis feed drive testbed was used to evaluate the cycle time estimation accuracy of the proposed algorithm.

We propose the measurement method for location errors in a horizontal 4-axis machine tool using a touch trigger probe and a sphere artifact. Location errors (type of geometric errors), are values that do not change with the position of each feed axis because these errors are usually fixed in an assembly procedure. There are seven location errors in a horizontal 4-axis machine tool; three squareness errors in three linear axes and two squareness and two offset errors in a rotary axis. The positions of center point of sphere artifact on a rotary axis are measured by a touch trigger probe mounted on a tool axis. Because measured center points are expressed by seven location errors via the homogeneous transformation matrix, location errors can be separated by analyzing measured data. To validate the proposed method, measurement experiments were performed on a horizontal 4-axis machine tool. Measurement results were verified by comparing before and after compensation.

Temperature characteristics of supply oil in an ultra-precision hydrostatic table are largely influenced by parameter setting in an oil cooler such as the location of reference sensor and cooling temperature. In this paper, influences of the parameter setting on the temperature variation in the hydrostatic table are experimentally analyzed to suggest the guidelines for practical application. In case of using temperature of inlet oil as a reference sensor in the oil cooler, temperature rise of the supply oil is smaller and thermal settling time is faster than that of using temperature of outlet oil as a reference sensor. The experimental results also show that temperatures of table, rail and return oil can be made almost same, and thermal settling time can be decreased by setting cooling temperature in the oil cooler to be lower than atmospheric temperature.

This paper presents the motion accuracy simulation considering loads such as workpiece weight, cutting force, cogging force of a linear motor, and force caused by misalignment and runout error of a ballscrew in linear motion units. The transfer function method is basically utilized to estimate 5-DOF motion errors, together with the equilibrium equations of force and moment on the table. The transfer function method is modified in order to consider clearance changed according to the loads in the double sided hydrostatic/aerostatic bearings. Then, the analytic model for predicting the 5-DOF motion errors is proposed with the modified transfer function method. Motion errors were simulated under different loading conditions in the linear motion units using hydrostatic, aerostatic, and linear motion bearings, respectively. And the proposed analytic model was verified by comparing the estimated and measured motion errors.

Diffractive optical elements (DOEs) ? in general a complex pattern of micro- and nano-scale structures ? can modulate and transform light in a predetermined way. Their importance is being increased nowadays because they can be designed to handle a number of simultaneous tasks. In view point of machining DOEs, it is a big challenge to fabricate micro- and nano-scale structures on a free-form surfaces. In this paper, the state-of-the-art of the ultra-precision machine tools is reviewed. Also some technical issues which determine the machine tool accuracy are discussed.

We report an ultra-precision lathe designed to machine micron-scale features on a large-area roll mold. The lathe can machine rolls up to 600 ㎜ in diameter and 2,500 ㎜ in length. All axes use hydrostatic oil bearings to exploit the high-precision, stiffness, and damping characteristics. The headstock spindle and rotary tooling table are driven by frameless direct drive motors, while coreless linear motors are used for the two linear axes. Finite element method modeling reveals that the effects of structural deformation on the machining accuracy are less than 1 ㎛. The results of thermal testing show that the maximum temperature rise at the spindle outer surface is approximately 0.5 °C. Finally, performance evaluations of the error motion, micro-positioning capability, and fine-pitch machining demonstrate that the lathe is capable of producing opticalquality surfaces with micron-scale patterns with feature sizes as small as 20 ㎛ on a large-area roll mold.

We report a centerless grinding machine which can perform multi-function with 600 mm wide grinding wheels. By increasing manufacturing area, long workpiece such as camshaft and steering shaft, is allowed to grind more quickly, compared with cylindrical grinding system. In this paper, the design of centerless grinding machine puts emphasis on symmetry to exploit the thermal stability. Results of finite element analysis shows that the difference of the structural deflection in the front and rear guideways is less than 1.5 μm due to symmetric design. The difference is less than 3.0 μm, even though the thermal deformation is considered. According to the performance evaluation, the radial error motion of the G/W spindle, which is measured by applying Donaldson Ball Reversal, is about 1.1 μm. The yaw error of the G/W slide is improved from 2.1 arcsec to 0.5 arcsec by readjusting the slide preload and ball screw.

In this study, effect of the sensor gain error is theoretically analyzed and simulated when mixed sequential two-prove method(MTPM) is applied for the precision measurement of straightness error of a linear motion table. According to the theoretical analysis, difference of the gain errors between two displacement sensors increases measurement error dramatically and alignment error of the straightedge is also amplified by the sensor gain difference. On the other hand, if the gain errors of the two sensors are identical, most of error terms are cancelled out and the alignment error doesn’t give any influence on the measurement error. Also the measurement error of the straightness error is minimized compared with that of the straightedge’s form error owing to close relationship between straightness error and angular motion error of the table in the error terms.

The large surface micro machining system includes the equipments and processes for manufacturing the ultra precision micro patterned products with large surface through the mechanical machining. Recent major issue on the micro machining technology may be the development of optical parts for the back light unit of display which has the largest market. This special issue makes up with three parts; the large surface micro machining system and machine, machining process and forming process. In this paper, the state-of-the-art and core technology of large surface micro machining system is introduced with focus on the manufacturing technology for the back light unit of LCD TV. Then, some research results on the development of a roll die lathe is introduced which involves the concept of machine design, improvement of thermal characteristics in the spindle system, improvement of relative parallelism and straightness between spindle system and long stroke feed table, machining of micro pitch patterns. Finally, the direct forming process is introduced as the future work in the large surface micro machining field.

The accuracy simulation technology of linear motion system is introduced in this paper. Motion errors and positioning errors are simulated using informations on the design parameters of elements of linear motion system. 5 Degree-of-freedom motion error analysis algorithm utilizing the transfer function method and positioning error analysis algorithm which are main frame of accuracy simulation are introduced. Simulated motion errors are compared with experimental results for verifying the effectiveness. Then, using the proposed algorithms, simulation is performed to investigate the effects of ballscrew and linear motor on the motion errors. Finally, the influence of feedback sensor position on the positioning error is also discussed.

This paper presents bisymmetric dual iron core linear motor stage for heavy-duty high precision applications such as large area micro-grooving machines or high precision roll die machines. In this stage, two iron core linear motors are installed in laterally symmetric way to cancel out the attractive forces. Main focus was given to analyzing the effect of cogging force and moment for two different layouts, which are symmetric and half-pitch shifted ones. Experimental results showed that the symmetric layout is more adequate for high precision applications because of its clear moment cancellation effect. It was also verified that the effect of the residual cogging moment can be suppressed further by increasing the bearing stiffness. One problem of the symmetric layout is added cogging force which hinders smooth motion, but its effect was relatively small compared with that of moment cancellation

We discuss two possibilities of using femtosecond pulse lasers as a new interferometric light source for enhanced precision surface-profile metrology. First, a train of ultra-fast laser pulses yields repeated low temporal coherence, which allows unequal-path scanning interferometry, which is not feasible with white light. Second, the high spatial coherence of femtosecond pulse lasers enables large-sized optics to be tested in non symmetric configurations with relatively small-sized reference surfaces. These two advantages are verified experimentally using Fizeau and Twyman-Green type scanning interferometers.