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TECHNICAL PAPERS

Robust Machining Force Control With Process Compensation

[+] Author and Article Information
Sung I. Kim

TRW Systems, Redondo Beach, California 90278e-mail: sung.kim@trw.com

Robert G. Landers

University of Missouri-Rolla, Department of Mechanical and Aerospace Engineering and Engineering Mechanics, Rolla, Missouri 65409-0050e-mail: landersr@umr.edu

A. Galip Ulsoy

University of Michigan, Department of Mechanical Engineering, Ann Arbor, Michigan 48109-2125e-mail: ulsoy@umich.edu

J. Manuf. Sci. Eng 125(3), 423-430 (Jul 23, 2003) (8 pages) doi:10.1115/1.1580849 History: Received July 01, 2001; Revised December 01, 2002; Online July 23, 2003
Copyright © 2003 by ASME
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References

Jeppsson, J., 1988, “Adaptive Control of Milling Machines,” SME Technical Paper MS88-103, Advanced Machining Technology II, Phoenix, AZ, Feb. 16–18.
Ulsoy,  A. G., Koren,  Y., and Rasmussen,  F., 1983, “Principle Developments in the Adaptive Control of Machine Tools,” ASME J. Dyn. Syst., Meas., Control, 105(2), pp. 107–112.
Lauderbaugh,  L. K., and Ulsoy,  A. G., 1989, “Model Reference Adaptive Force Control in Milling,” ASME J. Eng. Ind., 111(1), pp. 13–21.
Altintas,  Y., 1994, “Direct Adaptive Control of End Milling Process,” Int. J. Mach. Tools Manuf., 34(4), pp. 461–472.
Harder, L., 1995, “Cutting Force Control in Turning—Solutions and Possibilities,” Ph.D. Dissertation, Department of Materials Processing, Royal Institute of Technology, Stockholm.
Landers, R. G., and Ulsoy, A. G., 1996, “Machining Force Control Including Static, Nonlinear Effects,” Japan USA Symposium on Flexible Automation, Boston, Massachusetts, July 8–10, pp. 983–990.
Landers,  R. G., and Ulsoy,  A. G., 2000, “Model-Based Machining Force Control,” ASME J. Dyn. Syst., Meas., Control, 122(3), pp. 521–527.
Chen,  B-S., and Chang,  Y-F., 1991, “Robust PI Controller Design for A Constant Turning Force System,” Int. J. Mach. Tools Manuf., 31(3), pp. 257–272.
Carrillo,  F. J., Rotella,  F., and Zadshakoyan,  M., 1999, “Delta Approach Robust Controller for Constant Turning Force Regulation,” Control Eng. Pract., 7(11), pp. 1321–1331.
Hayes, R. D., Shin, Y. C., and Nwokah, O. D. I., 1993, “Robust Control Design for Milling Processes,” DSC-Vol. 50/PED-Vol. 63, ASME Winter Annual Meeting, New Orleans, LA, Dec., pp. 119–125.
Punyko,  A. J., and Bailey,  F. N., 1994, “A Delta Transform Approach to Loop Gain-Phase Shaping Design of Robust Digital Control Systems,” Int. J. Robust Nonlinear Control, 4(1), pp. 65–86.
Nordgren, R. E., and Nwokah, O., 1994, “Parametric and Unstructured Uncertainty Models in Discrete Time Systems,” DSC Vol. 55-1, ASME Winter Annual Meeting, Chicago, IL, Nov. 6–11.
Rober,  S. J., Shin,  Y. C., and Nwokah,  O. D. I., 1997, “A Digital Robust Controller for Cutting Force Control in the End Milling Process,” ASME J. Dyn. Syst., Meas., Control, 119(2), pp. 146–152.
Landers, R. G., 1997, “Supervisory Machining Control: A Design Approach Plus Force Control and Chatter Analysis Components,” Ph.D. Dissertation, Department of Mechanical Engineering, University of Michigan, Ann Arbor, Michigan.

Figures

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Upper forward-loop transfer function (circles), lower forward-loop transfer function (squares), upper desired forward-loop transfer function (diamonds), lower desired forward-loop transfer function (triangles). Note the upper and lower desired forward-loop transfer functions coincide.
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Block diagram of robust machining force control system
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Simulation results. Case I (circles): robust control with process compensation with K=K̄,α=α_,β=β̄, and d=d̄. Case II (squares): robust control with process compensation with K=K_,α=ᾱ,β=β_, and d=d̄. Case III (diamonds): robust control without process compensation with K=K̄,α=α_,β=β̄, and d=d̄. Case IV (triangles): robust control without process compensation with K=K_,α=ᾱ,β=β_, and d=d_. For all cases Fr=0.285 kN and T=0.08 s. Note that the responses for Cases I and III coincide.
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Simulation results for robust controller with process compensation [d=d_ (circles), d=dnom (squares), and d=d̄ (diamonds)]. Simulation parameters: K=Knom,α=αnom,β=βnom,Fr=0.285 kN, and T=0.08 s.
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Simulation results for robust controller without process compensation [d=d_ (circles), d=dnom (squares), and d=d̄ (diamonds)]. Simulation parameters: K=Knom,α=αnom,β=βnom,Fr=0.285 kN, and T=0.08 s.
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Schematic of experimental system and part. The part is fed towards the tool in the negative x direction.
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Experimental results for robust controller with process compensation. Controller parameters: K=K̄,α=α_,β=β̄,d=d_,Fr=0.285 kN, and T=0.08 s.
Grahic Jump Location
Experimental results for robust controller with process compensation. Controller parameters: K=K_,α=ᾱ,β=β_,d=d̄,Fr=0.285 kN, and T=0.08 s.
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Experimental (circles) and simulation (squares) results for robust controller with process compensation. Simulation parameters: K=Knom,α=α_,β=βnom,d=3 mm,Fr=0.285 kN, and T=0.08 s.
Grahic Jump Location
Experimental (circles) and simulation (squares) results for robust controller with process compensation. Simulation parameters: K=Knom,α=ᾱ,β=βnom,d=3 mm,Fr=0.285 kN, and T=0.08 s.
Grahic Jump Location
Experimental (circles) and simulation (squares) results for robust controller with process compensation. Simulation parameters: K=K_,α=αnom,β=βnom,d=3 mm,Fr=0.285 kN, and T=0.08 s.
Grahic Jump Location
Experimental (circles) and simulation (squares) results for robust controller with process compensation. Parameters: K=K̄,α=αnom,β=βnom,d=3 mm,Fr=0.285 kN, and T=0.08 s.
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Experimental results for proposed robust controller with process compensation. Parameters: K=Knom,α=αnom,β=βnom,Fr=0.285 kN, and T=0.08 s.
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Experimental results for robust controller without process compensation. Parameters: K=Knom,α=αnom,β=βnom,Fr=0.285 kN, and T=0.08 s.

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