On The Knowledge and Experience of Programmer

Introduction
 Adaptive control system is a logical extension of the CNC-

mechanism.
 In CNC mechanism the cutting speed and feed rates are
prescribed by the part programmer.
 The determination of these operating parameters depends
on the Knowledge and experience of programmer
regarding the work piece, tool materials, coolant conditions
and other factors.
 By contrast in adaptive control machining, there is
improvement in the production rate and reduction in the
machining cost as a result of calculating and setting of optimal
parameters during machining.
Origin
 Adaptive control (AC) machining originated out of

research in early 1970’s sponsored by U.S Air
Force.
 The initial adaptive control systems were based on
analog devices, representing the technology at that
time.
 Today adaptive control uses microprocessor
based controls and is typically integrated with an
existing CNC system.
DEFINITION OF AC MACHINING
 For a machining operation the term AC denotes control

systems that measures certain output variables and
uses to control speed or
feed.
 Some of the process
variables that have
been used in AC
machining systems
include spindle deflection
or force, torque, cutting
temperature and horse
power.
 The adaptive control is basically a feedback
system that treats the CNC as an internal unit and
in which the machining variables automatically
adapt themselves to the actual conditions of the
machining process.
 Note:- IP (Performance Index) is usually an
economic function such as max production rate or
minimum machining cost.
Functions of AC
The three functions of adaptive control are:

• Identification function.
• Decision function.
• Modification function.
• The main idea of AC is the improvement of the cutting
process by automatic on line determination of speed
and/or cutting.
• The AC is basically a feedback system in which cutting
speed and feed automatically adapt themselves to
the actual condition of the process and are varied
accordingly to the changes in the work conditions as work
progresses.
IDENTIFICATION FUNCTIONS
 This involves determining the current

performance of the process or system .
 The identification function is concerned with
determining the current value of this
performance measure by making use of the
feedback data from the process.
DECISION FUNCTION
 Once the system performance is determined, the

next function is to decide how the control
mechanism should be adjusted to improve
process performance.
 The decision procedure is carried out by means of a
pre-programmed logic provided by the designer.

MODIFICATION FUNCTION
 The third AC function is to implement the decision.

 While the decision function is a logic function,
modification is concerned with a physical or
mechanical change in the system.
 The modification involves changing the
system parameters or variables so as to drive
the process towards a more optimal state.
WHERE TO USE ADAPTIVE CONTROL
 Adaptive control is not suitable for every machining

situation.
 In general, the following characteristics can be used to
identify situations where adaptive control can be
beneficially applied.
 The in-process time consumes a significant portion of
the machining cycle time.
 There are significant sources of variability in the job
for which AC can compensate.
 The cost of operating the machine tool is high.
 The typical jobs involve steels, titanium and high
strength alloys.
Classification of AC systems
In practice the AC system of machine tools can be

classified into two types:
 AC with optimization (ACO)
 AC with constrains (ACC)
 Geometric Adaptive Control (GAC)
ACC
 ACC are systems in which machining conditions such as

spindle speed or feed rate are maximized within the
prescribed limits of machines and tool constrains such as
maximum torque, force or horse power.
 In AC system the correct feed and speed are automatically
found and it is not necessary to spend efforts on calculations
of optimum feeds and speeds.
 ACC systems do not utilize a performance index and are based
on maximizing a machining variable (e.g., feed rate)
subject to process and machine constraints (e.g., allowable
cutting force on the tool, or maximum power of the machine).
 The objective of most ACC types of systems is to increase the
MRR during rough cutting operations.
Basic Structure of ACC
ACC Example
 For example, to maximize the machining feedrate while maintaining

a constant load on the cutter, despite variations in width and depth of
cut.
 In a normal CNC system, the feedrate is programmed to
accommodate the largest width and depth in a particular cut, and this
small feedrate is maintained along the entire cut. As a result the
machining rate is reduced.
 By contrast, with the ACC system, the maximum allowable load
(e.g., cutting force) on the cutter is programmed.
 As a result, when the width or depth of cut are small the feedrate is
high; when either the width or depth of cut (or both) are increased,
the feedrate is automatically reduced, and consequently the allowable
load on the cutter is not exceeded.
 The result is, the average feed with ACC is much larger than its
programmed counterpart.
ACO System
 The ACO Systems for N/C machine tools is a control

system that optimizes performance index
subjects to various constraints.
 It is basically a sophisticated closed loop control
system, which automatically works in optimum
conditions, even in the presences of work piece and
tools materials variations.
Basic Structure of ACO System
Drawback of ACO
 The main problem is that this require on-line measurement
of tool wear.
 So far there have been no industrially acceptable
methods developed for the direct measurement of tool wear.
 Indirect measurement assumes that tool wear is proportional
to other measurable variables such as cutting forces and
temperatures.
 The drawback of using these indirect measurements
is that variations in their values can be caused by process
variations other than tool wear, such as workpiece hardness or
cutting conditions.
 Thus making it difficult to identify the tool wear effect from
the effect of the other parameter variations on the
measurements.
GEOMETRIC ADAPTIVE CONTROL
 GAC are typically used in finish machining

operations.
 In GACs the part quality is maintained in real time by
compensating for the deflection and wear of cutting
tools.
 The objective of GAC is to achieve:-
 (1) the required dimensional accuracy and
 (2) a consistency of surface finish of machined parts
despite tool wear or tool deflection
Drawback of GAC
 Both the dimensional accuracy and the

surface finish are affected by the flank wear and the
crater wear of the tools which deteriorate during
cutting.
 These variables cannot be measured in real time;
neither can they be accurately predicted from off-line
tool testing.
Benefits of AC
 Increased production rates.

 Increased tool life.
 Greater part protection.
 Less operator intervention.
Limitations
 A major drawback is the unavailability of suitable

sensors that have a reliable operation in a
manufacturing environment . (Tool wear sensor).
 Another problem is the interface of an AC system
with CNC units. As yet, manufacturers have not
standardized interfaces.
Sources
 Adaptive Control Systems for Machining by YORMI KOREN

Dept of Mechanical Engineering and Applied Mechanics,
The University of Michigan.
 CAD/CAM Computer aided design and Manufacturing,
M.P.Groover

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Introduction

 Adaptive control system is a logical extension of the CNC-

 Adaptive control (AC) machining originated out of

 For a machining operation the term AC denotes control

The three functions of adaptive control are:

 This involves determining the current

 Once the system performance is determined, the

 The third AC function is to implement the decision.

 Adaptive control is not suitable for every machining

In practice the AC system of machine tools can be

 ACC are systems in which machining conditions such as

 For example, to maximize the machining feedrate while maintaining

 The ACO Systems for N/C machine tools is a control

 GAC are typically used in finish machining

 Both the dimensional accuracy and the

 Increased production rates.

 A major drawback is the unavailability of suitable

 Adaptive Control Systems for Machining by YORMI KOREN

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