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Model reference-based machining force and surface roughness control
Čuš, Franc, 1953- ; Župerl, Uroš
Purpose: The main objective of this paper is to present the development of an empirical model-based control mechanism to maintain a fine surface finish quality by maintaining on-line cutting values. ...Design/methodology/approach: The proposed model has been developed to present the control model constraints, by varying the machining parameters to control the force output to be constant. Genetic programming method (GP) has been applied to derive empirical relationship of the surface finish and the cutting force. These relationships have been applied to develop the proposed simulation model, in which the cutting force is adjusted to improve the required surface finish for the end milling operation process. Findings: The experimental results show that not only does the milling system with the design controller have high robustness, and global stability but also the machining efficiency of the milling system with the adaptive controller is much higher than for traditional CNC milling system. Experiments have confirmed efficiency of the adaptive control system, which is reflected in improved surface quality and decreased tool wear. Research limitations/implications: The proposed architecture for determining of optimal cutting conditions is applied to ball-end milling in this paper, but it is obvious that the system can be extended to other machines to improve cutting efficiency. Practical implications: The results of experiments demonstrate the ability of the proposed system to effectivelv regulate peak cutting forces for cutting conditions commonly encountered in end milling operations. The high accuracv of results within a wide range of machining parameters indicates that the system can be practically applied in indusm. Originality/value: By the GP modeling the system for adaptive adjustment of cutting parameters is built.
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