Computer control of a machining system that involves the CAD/CAM based support has been widely accepted to improve productivity and reduce production cost. Recently, more intelligent functions have been developed and integrated into CNC machine tools. CAD/CAM provides the facilities to create and monitor tool paths to use on the workpiece. In some CAM software programs, machine tools and machine virtual environments can be utilized to dynamically simulate the machining operations. These dynamic simulations provide NC program generation and verification, material removal analysis and collision detection error. With the process simulation, the tool path can be analyzed and verified before actually machining the part. It has become easier to machine complex parts more accurately and more quickly with the advancement of simulation tools. However, in selection of machining strategies, the methods offered by CAM software often are based on the parts' geometrical information with little or no consideration of the machine tool capability or the physics of metal cutting. On the other hand, machine tools (or operators) have limited information about NC programs, hence it is difficult to judge whether machining is performed properly. Running machine tools under undesirable operating conditions can cause damage to tools, the machine tools or workpiece. Operating at, near or over the machine limits, for a short time or over a long period of time, can lead to damage to the tool, the machine tool or workpiece.
Moreover, in practice, operating parameters are still mainly selected based on either on machining handbooks and/or tool manufacturer's catalogues which are typically very conservative and aggressive, respectively. Therefore, it has been difficult to perform the machining under an optimal condition, which either leads to low productivity or deterioration in machining accuracy and surface roughness. Moreover, when the tool is a cutting tool which is engaged in cutting with a rapidly increasing cutting load, damage easily occurs to the cutting tool as well as work material to be machined.