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1 Journal of Achievements in Materials and Manufacturing Engineering

1 2008

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Model reference adaptive force and surface roughness control in milling

Cus F., Zuperl U.

Journal of Achievements in Materials and Manufacturing Engineering

2008

Vol. 26, nr 2

179-182

Purpose: of this paper. The paper presents the model based mechanism of control assuring constant quality of surface finish by controlling the cutting forces in the end milling process. By dynamic adaptation of feeding and speed the system controls the surface roughness and the cutting forces on the milling cutter. The purpose of developing such a mechanism is to find the limitations of such control which maintains constant cutting force by adapting the cutting parameters. Design/methodology/approach: The model based system of control has been developed by the evolutionary method of genetic programming (GP). A drawing of experiments has been made in order to determine the empirical correlations between the quality of surface finish and the cutting force. Genetic programming method has been applied to derive empirical relationship of the surface finish and cutting force values for steel material. These relationships have been applied to develop the proposed evolution simulation model in which the cutting force is adjusted to improve the required surface quality. Findings: The system eliminates the problems related to assurance of quality of machining, efficiency of machining and prevention of tool damages. Research limitations/implications: While force control approach performed satisfactorily in a laboratory environment, it can be generally concluded that their implementation should be dictated by the economics of the production environment. Practical implications: The results provide a means of greater efficiency by improving the surface quality, minimizing the effect of the process variability and reducing the error cost in finishing operations. Originality/value: An adaptive system of control which controls the cutting force and maintains constant roughness of the machined surface during milling by continuous dynamic adjustment of the cutting parameters is devolped.