High-Speed End Milling Using a Feedforward Control Architecture

[+] Author and Article Information
E. D. Tung, M. Tomizuka

Department of Mechanical Engineering, University of California, Berkeley, Berkeley, CA 94720

Y. Urushisaki

Matsuura Machinery Corp., Fukui, Japan

J. Manuf. Sci. Eng 118(2), 178-187 (May 01, 1996) (10 pages) doi:10.1115/1.2831010 History: Received October 01, 1993; Revised August 01, 1994; Online January 17, 2008


Experiments are performed for end milling aluminum at 15,000 RPM spindle speed (1,508 m/min cutting speed) and up to 3 m/min table feedrate using an experimental machine tool control system. A digital feedforward controller for feed drive control incorporates the Zero Phase Error Tracking Controller (ZPETC) and feedforward friction compensation. The controller achieves near-perfect (±3 μm) tracking over a 26 mm trajectory with a maximum speed of 2 m/min. The maximum contouring error for a 26 mm diameter circle at this speed is less than 4 μm. Tracking and contouring experiments are conducted for table feedrates as high as 10 m/min. Frequency domain analysis demonstrates that the feedforward controller achieves a bandwidth of 10 Hz without phase distortion. In a direct comparison of accuracy, the machining errors in specimens produced by the experimental controller were up to 20 times smaller than the errors in specimens machined by an industrial CNC.

Copyright © 1996 by The American Society of Mechanical Engineers
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