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Technical Brief

Adaptive Robust Control of Circular Machining Contour Error Using Global Task Coordinate Frame

[+] Author and Article Information
Tyler A. Davis

Mem. ASME
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907-2088
e-mail: zip.tyler@gmail.com

Yung C. Shin

Fellow ASME
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907-2088
e-mail: shin@purdue.edu

Bin Yao

Fellow ASME
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907-2088
e-mail: byao@purdue.edu

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received February 18, 2013; final manuscript received September 16, 2014; published online November 26, 2014. Assoc. Editor: Robert Landers.

J. Manuf. Sci. Eng 137(1), 014501 (Feb 01, 2015) (8 pages) Paper No: MANU-13-1068; doi: 10.1115/1.4028634 History: Received February 18, 2013; Revised September 16, 2014; Online November 26, 2014

The contour error (CE) of machining processes is defined as the difference between the desired and actual produced shape. Two major factors contributing to CE are axis position error and tool deflection. A large amount of research work formulates the CE in convenient locally defined task coordinate frames that are subject to significant approximation error. The more accurate global task coordinate frame (GTCF) can be used, but transforming the control problem to the GTCF leads to a highly nonlinear control problem. An adaptive robust control (ARC) approach is designed to control machine position in the GTCF, while additionally accounting for tool deflection, to minimize the CE. The combined GTCF/ARC approach is experimentally validated by applying the control to circular contours on a three axis milling machine. The results show that the proposed approach reduces CE in all cases tested.

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Figures

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Fig. 2

Circular cut arrangement, tool path indicated by dotted line

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Fig. 3

Comparison of simulated and experimental X axis response to 16.2 Hz sinusoidal input

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Fig. 4

Bode plot of original and simplified X axis models

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Fig. 5

Bode plot of original and simplified Y axis models

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Fig. 6

Experimental and model results for average milling peak force

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Fig. 7

Overview of deflection analysis components

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Fig. 8

Simulated CE for control method in Ref. [17]

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Fig. 9

Simulated CE for the GTCF/ARC approach

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Fig. 10

Measured CE for uncontrolled case with feedrate of 7.37 mm/s

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Fig. 11

Measured CE for controlled case with feedrate of 6.52 mm/s

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Fig. 12

Measured CE for controlled case with feedrate of 7.37 mm/s

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Fig. 13

Measured CE for controlled case with feedrate of 8.21 mm/s

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Fig. 14

Online parameter estimates for 8.21 mm/s case (typical of other cases). The peak at π/2 is due to startup transients.

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