A smart tool system may include at least one assembly of a tool holder and a tool, and a tooling machine configured to rotate the at least one assembly to cut a workpiece. The tooling machine may have a spindle to which the tool holder may be selectively attachable, and a controller configured to rotate the spindle at a spindle speed. The smart tool system may also include at least one database configured to store vibrational data relating to at least one of the at least one assembly and the tooling machine. The smart tool system may further be configured to determine an optimum operating value and/or range of optimum operating values of at least one parameter for the tooling machine based on the vibrational data. The optimum operating value(s) provide for minimized or no chatter when cutting the workpiece.

A machining condition determining apparatus (1) includes a first setter (2a) setting a cutting speed of a cutting tool, a storage (3) storing a maximum output value of a drive motor rotating a spindle holding the cutting tool and a number of revolutions of the drive motor corresponding to the maximum output value, a number-of-revolutions determiner (4) obtaining a steady-state value of the maximum output value of the drive motor stored in the storage (3) and determining a number of revolutions of the drive motor corresponding to the obtained steady-state value of the maximum output value, and a tool-diameter determiner (5) calculating a tool diameter of the cutting tool based on the cutting speed set by the first setter (2a) and the number of revolutions of the drive motor determined by the number-of-revolutions determiner (4).

An embodiment of the present invention provides a machining system that can lengthen the lifespan of a tool and improve the machining quality of a workpiece by managing the amount of wear of the tool by machining the workpiece using the other portion of the tool when a portion of the tool is worn and the machining performance of the tool is decreased. The machining device for controlling a tool position considering tool wear according to an embodiment of the present invention includes: a tool-moving unit coupled to the machining unit and moving the machining unit to change the position of the tool with respect to the workpiece; a supporting unit supporting the workpiece and moving the workpiece to change the position of the workpiece with respect to the tool; a sensor unit disposed at the machining unit and measuring a current amount, which is supplied to a machining motor operating the tool, or an operation force of the tool; and a control unit receiving a measurement signal from the sensor unit and transmitting a control signal to the tool-moving unit and the supporting unit.

A method for predicting and compensating frictions of a feed system includes following steps: constantly obtaining current signals and angle-position signals of a motor by a motor driver of a feed system after being activated; calculating frictions of the motor upon each rotating position according to the obtained current signals and angle-position signals and generating multiple records of friction data; creating a friction model according to the multiple records of friction data and the angle-position signals each respectively corresponding to each record of friction data with respect to each rotating position; importing current angle-position signal of the motor to the friction model for predicting a predicted friction; calculating a compensation current based on the predicted friction; and, controlling the motor driver to additionally provide the compensation current to the motor for conquering an upcoming friction of the feed system approximate to the predicted friction.

A motion control system and a motion control method are provided. The motion control method includes: sending a plurality of machining commands to a second controller by a first controller at a cloud; storing the plurality of machining commands in a buffer by the second controller; and operating the machine tool according to the plurality of machining commands stored in the buffer. As such, when poor communication occurs between the first controller and the second controller, the second controller causes the buffer to send a deceleration command to the machine tool so as to cause the machine tool to operate at a reduced speed, thereby avoiding unexpected motion such as sudden shutdown of the machine tool and damage to machined products.

An error compensation system for a numerical control (NC) machine tool based on iterative learning control, including a trajectory generating module, a down-sampling module, a position controller, a first holder, a velocity-loop iterative learning controller, a velocity controller, a second holder and a control plant. The trajectory generating module is configured to generate a desired trajectory command including a first sampling command. The first sampling command is transmitted to the down-sampling module and the velocity-loop iterative learning controller. The first sampling command is down-sampled through the down-sampling module to obtain a second sampling command. The velocity-loop iterative learning controller is configured to receive the first sampling command, and obtain a first sampling error compensation sequence according to a first sampling error sequence and a first sampling error compensation sequence of a previous iteration machining process stored therein. An error compensation method is also provided herein.

A wire electrical discharge machine performs electrical discharge machining on a workpiece by applying voltage across an electrode gap formed between a wire electrode and the workpiece to thereby generate electrical discharge while moving the wire electrode relative to the workpiece along a path specified by a machining program. The wire electrical discharge machine includes: a voltage detector for detecting a gap voltage across the gap; a facing area calculation unit for calculating, as a facing area, the area of a surface of the workpiece contained within a predetermined distance from the center axis of the wire electrode; an axis feed rate determination unit for determining an axis feed rate based on the gap voltage value detected by the voltage detector, and the facing area; and a movement control unit for performing control so that the wire electrode moves relative to the workpiece at the axis feed rate.

A numerical value controller includes a storage unit that stores a machining program involving executing a plurality of canned cycles each including a first operation for positioning a drilling position of a workpiece relative to a tool, a second operation for moving the tool from a return point to a hole bottom point, and a third operation for moving the tool from the hole bottom point to the return point; a control unit that controls movement between the tool and the workpiece based on the machining program and that moves the tool along curved paths by starting the second operation before the first operation ends and starting the first operation in a subsequent canned cycle before the third operation ends; a distance calculating unit that calculates a retraction distance; and a curvature calculating unit that reads a positioning command for the drilling position for the subsequent canned cycle.

Feed rate scheduling methods include measuring a topography of a grinding wheel of a machine tool, calculating a topography parameter using the topography, and calculating a feed rate scheduling parameter for a toolpath of the grinding wheel based on the topography parameter. The topography may be measured using microscopy. The topography parameter may include a plurality of parameters including a density of crystals at a given depth (C(h)) of the grinding wheel and/or an area fraction of crystals protruding at a given depth (α(h)) of the grinding wheel. The feed rate scheduling parameter may include a grinding wheel feed rate, a grinding wheel spin rate, and/or a grinding wheel cutting depth, among other parameters.

A feed rate scheduling method may comprise: receiving an engagement geometry of a subtractive component for use in a computer numerical control (CNC) machining process; receiving a tool path for forming a component from a workpiece via the CNC machining process; calculating a plurality of bending moments of a spindle at various intervals along the tool path; and determining a feed rate schedule for the tool path of the subtractive component based on the plurality of bending moment.