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Conventional computer numerical controllers used for machine tools are not amenable to the adaptation to dynamic changes in operations and environments due to the proprietary closed architecture. This paper presents the design and development of a distributed open architecture controller for machine tools, which exhibits openness, modularity, and other desirable characteristics. With application of the object-oriented methodology, fundamental agents related to machine tool systems are identified and distributed system architecture is achieved. In addition to the overall system design, a main environment of the open architecture controller is developed to integrate existing function modules and to provide an application developing platform. Process monitoring and control schemes developed within this system, as a case study, are presented.

Dynamics of machine tool components play a critical role in the outcome of machining processes. This paper addresses several important issues on machine tool and machining dynamics. It illustrates the dynamic behavior of structural components under operating conditions and presents an improved technique for modeling structural non-linearity. It also describes spindle modeling capability that has been developed to predict dynamic and thermal characteristics of spindle systems. Finally, the paper discusses the impact of non-linear dynamics on machining stability.

This paper presents in-process monitoring and control based on a novel ultrasonic sensing technique. The developed ultrasonic system provides non-contact measurement of surface roughness, which is applicable to wet machining environments. The utility and robustness of the technique are demonstrated through applications to different processes and materials. In-process surface roughness monitoring capability of the system is also shown along with its potential to monitor flank wear conditions. The result of in-process surface roughness control implementation based on the developed technique shows the control scheme is able to maintain consistent surface roughness values regardless of the tool wear state.