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Research Papers

An Adaptive Fuzzy Controller for Constant Cutting Force in End-Milling Processes

[+] Author and Article Information
Chengying Xu, Yung C. Shin

School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907

J. Manuf. Sci. Eng 130(3), 031001 (May 02, 2008) (10 pages) doi:10.1115/1.2823070 History: Received April 13, 2007; Revised October 18, 2007; Published May 02, 2008

A novel multilevel fuzzy control system is introduced and implemented for online force control of end-milling processes to increase machining productivity and improve workpiece quality, where the cutting force is maintained at its maximum allowable level in the presence of different variations inherent in milling processes, such as tool wear, workpiece geometry, and material properties. In the controller design, the fuzzy rules are generated heuristically without any mathematical model of the milling processes. An adaptation mechanism is embedded to tune the control parameters online, and the resultant closed-loop system is guaranteed to be stable based on the input-output passivity analysis. In the experiment, the control algorithm is implemented using a National Instrument real-time control computer in an open architecture control environment, where high metal removal rates are achieved and the cycle time is reduced by up to 34% over the case without any force controller and by 22% compared with the regular fuzzy logic controller, thereby indicating its effectiveness in improving productivity for actual machining processes.

Copyright © 2008 by American Society of Mechanical Engineers
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References

Figures

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Figure 2

Fuzzy MFs for input and output variables

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Figure 3

Simulation result of the MLFC controller

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Figure 4

Simulation result of the direct adaptive controller

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Figure 5

Cross section of workpiece in the simulation

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Figure 6

Simulation result of the MLFC controller

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Simulation result of the extended MRAC controller

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Figure 17

Force signals, control signal, and output MFs with MLFC controller

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Figure 16

Force signals, control signal, and output MFs with regular FLC controller

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Force signals and control signal without any force controller

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Cross section of workpiece in the end-milling process

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Figure 13

Force signals, control signal, and output MFs with MLFC controller

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Figure 12

Force signals, control signal, and output MFs with regular FLC controller

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Figure 11

Force signals and control signal without any force controller

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Figure 10

Cross section of workpiece in the end-milling process

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Figure 9

Experimental setup for milling force control

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Figure 8

PC-based controller interface for a CNC machine using digital communication

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