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    Adaptive Control of Cutting Force For End Milling Processes: Motivation

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    bspgitam
    An adaptive controller was developed to maintain a constant cutting force during end milling operations with varying cutting conditions. The controller adjusts the feedrate in real-time to account for changes in cutting parameters. Testing on a CNC milling machine showed the adaptive controller was able to maintain a constant cutting force when the depth of cut varied, unlike a fixed controller which produced step changes in force. The adaptive control scheme improved stability and reduced input oscillation compared to standard adaptive control methods.

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    Adaptive Control of Cutting Force For End Milling Processes: Motivation

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    bspgitam
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    An adaptive controller was developed to maintain a constant cutting force during end milling operations with varying cutting conditions. The controller adjusts the feedrate in real-time to account for changes in cutting parameters. Testing on a CNC milling machine showed the adaptive controller was able to maintain a constant cutting force when the depth of cut varied, unlike a fixed controller which produced step changes in force. The adaptive control scheme improved stability and reduced input oscillation compared to standard adaptive control methods.

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    An adaptive controller was developed to maintain a constant cutting force during end milling operations with varying cutting conditions. The controller adjusts the feedrate in real-time to account for changes in cutting parameters. Testing on a CNC milling machine showed the adaptive controller was able to maintain a constant cutting force when the depth of cut varied, unlike a fixed controller which produced step changes in force. The adaptive control scheme improved stability and reduced input oscillation compared to standard adaptive control methods.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    22 views3 pages

    Adaptive Control of Cutting Force For End Milling Processes: Motivation

    Uploaded by

    bspgitam
    An adaptive controller was developed to maintain a constant cutting force during end milling operations with varying cutting conditions. The controller adjusts the feedrate in real-time to account for changes in cutting parameters. Testing on a CNC milling machine showed the adaptive controller was able to maintain a constant cutting force when the depth of cut varied, unlike a fixed controller which produced step changes in force. The adaptive control scheme improved stability and reduced input oscillation compared to standard adaptive control methods.

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    © All Rights Reserved
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    of 3

    Intelligent Manufacturing Laboratory at Purdue University

    Adaptive Control of Cutting Force for End Milling Processes


    Motivation

    Fixed controllers are designed for nominal plants and effectiveness diminishes as the
    cutting parameters vary.
    Varying gains and dynamics require conservative feedrate settings for fixed control
    systems
    Maintaining desired cutting forces prolongs tool life increasing productivity
    Standard MRAC has the following limitations:
    - Introduces instability for nonminimum phase zeros
    - Large input signal oscillation possible

    Approaches:

    Develop an adaptive control scheme to maintain constant cutting force during end
    milling for time-varying cutting conditions.
    Augment the performance index of the controller to reduce input signal oscillation.
    Implement the adaptive control scheme on a high speed milling machine through a
    PC-based open architecture.

    Results:

    An adaptive controller has been designed that will maintain a constant cutting force
    for milling operations by controlling the feedrate of the table.
    Extended MRAC designs offer an improvement over the Standard MRAC system in
    its ability to control nonminimum phase plants.
    Augmented Performance Index can effectively reduce input oscillation which is
    detrimental to machine life.
    A PC based open architecture controller was designed to control CNC machines, thus
    allowing the testing of new algorithms.
    Experimental implementation was performed using a workpiece containing two
    changes in the axial depth of cut (Figure 2). While machining with a fixed parameter
    controller showed step changes in cutting force due to the depth of cut changes
    (Figure 3), the tests performed with the developed adaptive controller for various
    radial depths of cut under varying machining conditions produced constant cutting
    force (Figure 4).

    Intelligent Manufacturing Laboratory at Purdue University

    Tachometer

    Spindle
    Motor
    Cutting Tool
    Amplifier
    Workpiece
    Dynamometer

    Lead
    Screw

    Table
    Motor

    Tachometer

    Feed Table
    Amplifier

    PC #1

    PC #2

    Force Monitoring

    Adaptive Controller
    User Interface
    Real-Time Display

    Figure 1. Experimental set for adaptive cutting force control on a high speed milling
    machine.

    50 mm
    50 mm

    50 mm
    Axial DOC

    10 mm

    20 mm
    10 mm

    Direction of Travel

    Figure 2 - Cross Section of Workpiece Used in End Milling Experiments

    Intelligent Manufacturing Laboratory at Purdue University

    Input Signal
    1

    (V)

    0.8
    0.6

    DOC=10mm

    DOC=20mm

    DOC=10mm

    0.4
    0.2
    0
    0

    10

    15
    Time (sec)

    20

    25

    30

    20

    25

    30

    Force Level
    2500

    (N)

    2000
    1500
    1000
    500
    0
    0

    10

    15
    Time (sec)

    Overshoot: 30 %, Settling Time: 3 Seconds


    Sampling Period: 20ms, Cutter Speed: 1500rpm
    Figure 3. Constant input force response without adaptive control.

    Input Signal
    1

    (V)

    0.8

    DOC=10mm

    DOC=20mm

    DOC=10mm

    0.6
    0.4
    0.2
    0
    0

    10

    15

    20

    25

    15

    20

    25

    Time (sec)
    Force Level
    2500

    (N)

    2000
    1500
    1000
    500
    0
    0

    10
    Time (sec)

    Figure 4. Input signal and force level with the adaptive controller
    (0.080" DOC, W=10,000)

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