Virtual Machining State Imaging for Tool-Workpiece Diagnosis

The patent creates virtual copies of the workpiece and tool in a virtual space that replicate the physical machining process. These virtual models are moved according to actual motion data from the NC machine tool, enabling both accurate cutting load prediction and comprehensive representation of machining state phenomena including contact states, vibrations, and surface roughness without requiring multiple separate measurement systems

The virtual machining system serves multiple functions simultaneously: it predicts cutting loads, represents contact states between tool and workpiece, analyzes vibrations, and estimates surface roughness. This multi-functional approach resolves the contradiction by enabling comprehensive machining state representation while maintaining prediction accuracy through the use of actual motion data from the NC machine tool

Instead of using complex sensor systems to directly measure machining state, the patent creates simplified virtual models that replicate the essential geometry and motion of the workpiece and tool. These virtual copies are computationally efficient to manipulate while still providing objective recognition of machining state through their movement and interaction in the virtual space

The patent replaces complex mechanical measurement systems with computational models. Rather than using multiple sensors to detect contact states, vibrations, and forces, the system uses virtual models that are moved according to NC program data, substituting mechanical complexity with computational processing that achieves the same information gathering objectives