Direct adaptive control of end milling process

TLDR: In this paper, a direct adaptive control algorithm, which is spindle speed and drive dynamics independent, has been developed for machining operations, where the combined dynamics of feed motion and cutting process are modelled as a third order system whose parameters may vary with spindle speeds and part geometry changes during machining.

Abstract: A direct adaptive control algorithm, which is spindle speed and drive dynamics independent, has been developed for machining operations. The combined dynamics of feed motion and cutting process are modelled as a third order system whose parameters may vary with spindle speed and part geometry changes during machining. The algorithm does not use any specific time interval, thus sampling time dependent discrete transfer functions and pole assignments are avoided. The adaptive controller is designed to have a closed loop characteristic function which behaves like an open loop regular and stable machining operation. The proposed direct adaptive controller is practical, can be used in any multi-axes machining, and can be combined with chatter suppression techniques which require spindle speed regulation. The algorithm is applied to the adaptive control of milling. Satisfactory results are obtained in constraining the maximum cutting forces and dimensional surface errors in milling experiments.