An interpretive look at 20th century research on modeling of machining

Modeling of machining has evolved through three main stages over the years, namely empirical modeling, science-based (predictive) modeling, and computer-based modeling. All three of these now co-exist and synergize each other. Empirical modeling can be said to have had its beginning as an organized process in the late 1890s to early 1900s. Science-based modeling began to emerge in the 1940s and computer-based modeling in the 1970s. Each of these three stages was ushered in by a key event. The first originated with F. W. Taylor's pioneering engineering research and development of empirical methodology (and equations) for estimating reasonably economic machining conditions. The second stage was initiated largely by Merchant's physics-based modeling and analysis of the basic force system acting between the cutting tool, chip, and workpiece in a machining process. The third (and major) stage was the "watershed" event of the advent of digital computer technology and its application to manufacturing in general. This enabled integration of computer-based modeling with all of the databases of the full system of manufacturing. Today the synergistic combination of these three stages faces a significant challenge arising from the growing need for machine tools to be able to autonomously avoid or even correct processing errors or failures in process. Basic to advancement of such capability is to effect a continuing increase of the accuracy and realism of machining process models.