Adaptive Cutting Force Control with a Hybrid Axis System

Berend Denkena; Felix Flöter

doi:10.20965/ijat.2013.p0378

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IJAT Vol.7 No.4 pp. 378-384

doi: 10.20965/ijat.2013.p0378

(2013)

Paper:

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Adaptive Cutting Force Control with a Hybrid Axis System

Berend Denkena and Felix Flöter

Institute for Production Engineering and Machine Tools, Leibniz Universität Hannover, An der Universität 2, Garbsen 30823, Germany

Received:

February 1, 2013

Accepted:

May 29, 2013

Published:

July 5, 2013

Keywords:

milling machine, magnetic guide, adaptive control, hybrid axis system

Abstract

Cutting forces have a major effect on the results of a machining process. High loads on the tool can lead to surface geometry and surface roughness that are less than optimal. However, due to its high implementation costs, cutting force control is not often used on milling machines. The paper presents a new approach by integrating a hybrid axis system in the force control loop. This offers a more dynamic and accurate way to influence cutting forces, but it also results in a more complex control problem. Therefore, how the nonlinear and time-varying characteristics of the cutting process can be modeled and considered for an automated operation is comprehensively shown. The interaction of process estimation and control is demonstrated with a PID-Control structure. Experimental results are presented.

Cite this article as:

B. Denkena and F. Flöter, “Adaptive Cutting Force Control with a Hybrid Axis System,” Int. J. Automation Technol., Vol.7 No.4, pp. 378-384, 2013.

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References

[1] M. E. Matelotti, “An Analysis of the milling process,” Trans. of ASME 63, pp. 677-700, 1963.
[2] C. Brecher, R. Tuecks, R. Zunke, and C. Wenzel, “Development of a force controlled orbital polishing head for free form surface finishing,” Production Engineering, Vol.4, Issues 2-3, pp. 269-277, 2010.
[3] B. Denkena and C. Schmidt, “Experimental investigation and simulation of machining thin-walled workpieces,” Production Engineering, Vol.1, Issue 4, pp. 343-350, 2007.
[4] O. Masory and Y. Koren, “Adaptive control system for turning,” Annals of the CIRP, Vol.29, Issue 1, pp. 281-284, 1980.
[5] O. Masory and Y. Koren, “Adaptive control with process estimation,” Annals of the CIRP, Vol.30, Issue 1, pp. 373-376, 1981.
[6] Y. Altintas, “Direct Adaptive Control of End Milling Process,” Int. J. of Machine Tools & Manufacture, Vol.34, Issue 4, pp. 461-472, 1994.
[7] R. G. Landers, A. G. Ulsoy, and Y. H. Ma, “A comparison of modelbased machining force control approaches,” Int. J. ofMachine Tools & Manufacture, Vol.44, Issues 7-8, pp. 733-748, 2004.
[8] J. Z. Zhang and J. C. Chen, “The development of an in-process surface roughness adaptive control system in end milling operations,” Int. J. of Advanced Manufacturing Technology, Vol.31, Issues 9-10, pp. 877-887, 2007.
[9] A. T. Elfizy, G. M. Bone, and M. A. Elbestawi, “Design and control of a dual stage feed drive,” Int. J. of Machine Tools and Manufacture, Vol.45, pp. 153-165, 2005.
[10] T. Fujita, A. Matsubara, D. Kono, and I. Yamaji, “Dynamic characteristics and dual control of a ball screw drive with integrated piezoelectric actuator,” Precision Engineering, Vol.34, pp. 34-42, 2010.
[11] H. Shinno, H. Yoshioka, and H. Sawano, “A newly developed long range positioning table system with a sub-nanometer resolution,” CIRP Annals – Manufacturing Technology, Vol.60, pp. 403-406, 2011.
[12] Y.-T. Liu, R.-F. Fung, and C.-C. Wang, “Precision position control using combined piezo-VCM actuators,” Precision Engineering, Vol.29, pp. 411-422, 2005.
[13] B. Denkena, C.-C. Neuber, and F. Kallage, “Machine tool with a non-contacting adaptronic slide,” Adaptronic Congress, Göttingen, 2006.
[14] B. Denkena, C.-C. Neuber, and F. Kallage, “Adaptive Positionierung von Werkzeugmaschinenachsen mit kontaktlosen Antriebsund Führungssystemen,” 4, Paderborner Workshop, Entwurf mechatronischer Systeme, 2006.
[15] F. Kallage, “Einsatz magnetischer Aktor- und Führungseinheiten zur Erhöhung der Bahngenauigkeit von Hochgeschwindigkeitsfräsmaschinen,” Ph.D. Thesis, Leibniz Universität, Hannover, 2007.
[16] B. Denkena, F. Kallage, M. Ruskowski, K. Popp, and H. K. Tonshoff, “Machine tool with active magnetic guides,” CIRP Annals – Manufacturing Technology, Vol.53, Issue 1, pp. 3303-336, 2004.
[17] Y. Altintas, “Manufacturing Automation,” Cambridge University Press, 2000.
[18] C. G. Goodwin and K. S. Sin, “Adaptive Filtering Prediction and Control,” Prentice Hall, 1984.

This article is published under a Creative Commons Attribution-NoDerivatives 4.0 Internationa License.

[1] [1] M. E. Matelotti, “An Analysis of the milling process,” Trans. of ASME 63, pp. 677-700, 1963.

[2] [2] C. Brecher, R. Tuecks, R. Zunke, and C. Wenzel, “Development of a force controlled orbital polishing head for free form surface finishing,” Production Engineering, Vol.4, Issues 2-3, pp. 269-277, 2010.

[3] [3] B. Denkena and C. Schmidt, “Experimental investigation and simulation of machining thin-walled workpieces,” Production Engineering, Vol.1, Issue 4, pp. 343-350, 2007.

[4] [4] O. Masory and Y. Koren, “Adaptive control system for turning,” Annals of the CIRP, Vol.29, Issue 1, pp. 281-284, 1980.

[5] [5] O. Masory and Y. Koren, “Adaptive control with process estimation,” Annals of the CIRP, Vol.30, Issue 1, pp. 373-376, 1981.

[6] [6] Y. Altintas, “Direct Adaptive Control of End Milling Process,” Int. J. of Machine Tools & Manufacture, Vol.34, Issue 4, pp. 461-472, 1994.

[7] [7] R. G. Landers, A. G. Ulsoy, and Y. H. Ma, “A comparison of modelbased machining force control approaches,” Int. J. ofMachine Tools & Manufacture, Vol.44, Issues 7-8, pp. 733-748, 2004.

[8] [8] J. Z. Zhang and J. C. Chen, “The development of an in-process surface roughness adaptive control system in end milling operations,” Int. J. of Advanced Manufacturing Technology, Vol.31, Issues 9-10, pp. 877-887, 2007.

[9] [9] A. T. Elfizy, G. M. Bone, and M. A. Elbestawi, “Design and control of a dual stage feed drive,” Int. J. of Machine Tools and Manufacture, Vol.45, pp. 153-165, 2005.

[10] [10] T. Fujita, A. Matsubara, D. Kono, and I. Yamaji, “Dynamic characteristics and dual control of a ball screw drive with integrated piezoelectric actuator,” Precision Engineering, Vol.34, pp. 34-42, 2010.

[11] [11] H. Shinno, H. Yoshioka, and H. Sawano, “A newly developed long range positioning table system with a sub-nanometer resolution,” CIRP Annals – Manufacturing Technology, Vol.60, pp. 403-406, 2011.

[12] [12] Y.-T. Liu, R.-F. Fung, and C.-C. Wang, “Precision position control using combined piezo-VCM actuators,” Precision Engineering, Vol.29, pp. 411-422, 2005.

[13] [13] B. Denkena, C.-C. Neuber, and F. Kallage, “Machine tool with a non-contacting adaptronic slide,” Adaptronic Congress, Göttingen, 2006.

[14] [14] B. Denkena, C.-C. Neuber, and F. Kallage, “Adaptive Positionierung von Werkzeugmaschinenachsen mit kontaktlosen Antriebsund Führungssystemen,” 4, Paderborner Workshop, Entwurf mechatronischer Systeme, 2006.

[15] [15] F. Kallage, “Einsatz magnetischer Aktor- und Führungseinheiten zur Erhöhung der Bahngenauigkeit von Hochgeschwindigkeitsfräsmaschinen,” Ph.D. Thesis, Leibniz Universität, Hannover, 2007.

[16] [16] B. Denkena, F. Kallage, M. Ruskowski, K. Popp, and H. K. Tonshoff, “Machine tool with active magnetic guides,” CIRP Annals – Manufacturing Technology, Vol.53, Issue 1, pp. 3303-336, 2004.

[17] [17] Y. Altintas, “Manufacturing Automation,” Cambridge University Press, 2000.

[18] [18] C. G. Goodwin and K. S. Sin, “Adaptive Filtering Prediction and Control,” Prentice Hall, 1984.