A new methodology to generate instruction commands for prompt machine control as a replacement for the previously prepared numerical control (NC) programs is developed to realize an innovative intelligent machine tool. This machine tool can eliminate NC program preparation, achieve cutting process control, reduce the production lead time, and realize an autonomous distributed factory. In this study, the innovative intelligent machine tool based on the computer-aided manufacturing-computer NC integrated concept is developed. The special feature of this system is to generate instruction commands in real time for prompt machine control instead of using NC programs. Digital Copy Milling, which is a digitized version of traditional copy milling, is realized by using only the computer-aided design model of the product. In this system, the cutting-force simulation is performed simultaneously with the real-time tool path generation. Then, the tool feed rate can be controlled according to the predicted cutting force. Therefore, both the improvement of the machining efficiency and the avoidance of machining problems can be achieved. The instantaneous cutting force model predicts the cutting force. In this system, the work material is represented by the voxel model, and the uncut chip thickness is calculated discretely from the number of voxels removed. Thus, it is possible to predict the cutting force in the case of non-uniform contact between the tool and the work material. In this study, a machining simulation is conducted to validate the proposed method. The results of the simulation show successful tool feed speed adaptation based on the predicted cutting force. The results also show the effective reduction of the machining time. A case study of a custom-made product for dental prosthetics is examined as a good application of both the proposed adaptive control and the Digital Copy Milling system. Through this method, it is possible to improve the machining efficiency and prevent tool breakage.

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