ADAPTIVE CONTROL

PREPARED BY: DR. CHIRAG R. SANGHANI

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 INTRODUCTION
In CNC mechanism, the cutting parameters like speed and
feed rates are prescribed by the part programmer based
on the Knowledge and experience regarding the work
piece, tool materials, coolant conditions and other
factors.
B y contrast in adaptive control machining, there is
improvement in the production rate and reduction in the
machining cost as a result of calculating and setting of
optimal parameters during machining.
The Adaptive Control is basically a feedback system in
which cutting speed and feed automatically adapt
themselves to the actual condition of the process and are
varied accordingly to the changes in the work conditions
as work progresses.
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 Adaptive control (AC) machining originated out of
research in early 1970’s sponsored by U.S Air Force.
 It measures certain output variables and uses to control
speed or feed.
 Some of the process variables that have been used in AC
machining systems include spindle deflection or force,
torque, cutting temperature and horse power.

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 CLASSIFICATION OF AC SYSTEMS
 In practice the AC system of machine tools can be
classified into three types:
1) Adaptive control with optimization (ACO)
 In the ACO systems, machine settings are selected to
optimize a performance index such as production time,
unit cost, etc.
 Traditionally, ACO systems have dealt with adjusting
cutting parameters (feed-rate, spindle speed and depth
of cut) to maximise material removal rate subject to
constraints such as surface roughness, power
consumption, cutting forces, etc.

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 Other ACO systems optimise a multi-objective function
which are more practical in industrial applications

 For example, it is quite often to search the optimal

cutting parameters to minimize the cost of the operation,
maximize the production rate and maximize the part
quality.
2) Adaptive control with constraint (ACC)
 ACC are systems in which machining conditions such as
spindle speed or feed rate are maximized within the
prescribed limits of machines and tool constraints such
as maximum torque, force or horse power.

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 Typically, ACC systems are utilized in roughing
operations where material removal rate is maximized by
maintaining the cutting forces at the highest possible
cutting force such that the tool is not in danger of
breaking.
3) Geometric Adaptive Control (GAC)
 In GAC, the economic process optimization problem is
dominated by the need to maintain product quality such
as dimensional accuracy and/or surface finish.
 GAC systems are typically used in finishing operations
with the objective of maintaining a specific part quality
despite structural deflections and tool wear.

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 SOURCES OF VARIABILITY
 The following are the typical sources of variability in
machining where AC can be most advantageously
applied.
1)Variable geometry of cut in the form of changing
depth or width of cut: In these cases, feed rate is
usually adjusted to compensate for the variability.
2)Variable work piece hardness and Variable
machinability: When hard spots or other areas of
difficulty are encountered in a work piece, either speed
or feed is reduced to avoid premature failure of tool.
3)Variable work piece rigidity: If the work piece deflect
as a result of insufficient rigidity in set up, the feed rate
must be reduced to maintain accuracy in the process.
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4)Tool wear: It has been observed in research that as the
tool begins to dull, the cutting force increases. The
adaptive controller will typically respond to tool dulling
by reducing feed rate.
5) Air-gaps during cutting: During movement of tool from
one point to other without machining (air-gap), adaptive
controller will increase travelling speed of tool to
maximum for reduction of non-productive time.

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 ADVANTAGES OF AC
• Increased production rates
• Increased tool life.
• Greater part protection
• Less operator intervention

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 APPLICATIONS OF AC
• Flight control
• Power plant
• Cement industry
• Process industry
• Paper industry
• Chemical industry
• Steel and metallurgical industry
• Electrical drives

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THANK YOU

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