ADAPTIVE CONTROL

SYSTEM IN MACHINING
 INTRODUCTION
Adaptive control system is a logical extension of the CNC-
mechanism. In CNC mechanism the cutting speed and
feed rates are prescribed by the part programmer. The
determination of these operating parameters depends on
the Knowledge and experience regarding the work piece,
tool materials, coolant conditions and other factors.

By 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.
 INTRODUCTION
For a machining operation the term AC denotes control
systems that 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.
 Origin
Adaptive control (AC) machining originated out
of research in early 1970’s sponsored by U.S Air
Force.
The initial adaptive control systems were based
on analog devices, representing the technology
at that time.
 Today adaptive control uses microprocessor
based controls and is typically integrated with an
existing CNC system.
FUNCTIONS OF ADAPTIVE CONTROL
The three functions of adaptive control are:

1) Identification function

2) Decision function

3) Modification function.
 IDENTIFICATION FUNCTIONS
This involves determining the current
performance of the process or system .

The identification function is concerned with

determining the current value of this
performance measure by making use of the
feedback data from the process.
 DECISION FUNCTION
Once the system performance is determined, the next
function is to decide how the control mechanism
should be adjusted to improve process performance.
The decision procedure is carried out by means of a
pre-programmed logic provided by the designer.

Depending upon the logic the decision may be to

change one or more of the controllable process.
 MODIFICATION FUNCTION
The third AC function is to implement the
decision.
While the decision function is a logic function,
modification is concerned with a physical or
mechanical change in the system.
The modification involves changing the
system parameters or variables so as to drive the
process towards a more optimal state.
Figure below illustrates the sequence of the three
functions in an adaptive controller applied to a
hypothetical process
 TYPES OF ADAPTIVE CONTROL

There are basically two groups of adaptive

control:

Geometrical adaptive control.

Technological adaptive control.

 GEOMETRICAL ADAPTIVE CONTROL
This type of adaptive control is concerned with
monitoring the shape and dimension of a machined
component

The index of performance of such a system is the final

dimension and shape of the component.

 It may be said that the desired final goal of the

automated machining process is that the drawing of
the work piece to be machined component is the
output.
 TECHNOLOGICAL ADAPTIVE CONTROL

Under the umbrella of technological AC

two distinct systems are grouped:

Adaptive control constraint(ACC)

Adaptive control optimization(ACO)

 AC with constrains (ACC)
ACC are systems in which machining conditions
such as spindle speed or feed rate are maximized
with in the prescribed limits of machines and tool
constrains.

The most useful constraints in practical ACC

systems are the cutting force F, the cutting power
P, and the torque T.
 AC with constrains (ACC)
When the cutting force and torque are too high,
the cutter may break in bending or in twist. On the
other hand, for maximum productivity, the
maximum allowable feeds and cutting speed must
be used.

The principle of ACC system is to sense the

constraint variable and to adjust the cutting speed
and feed according to this measurement and a
programmed strategy.
 AC with constrains (ACC)
The advantage of this ACC system is that the
cutting tool is protected against catastrophic
failure simultaneously with keeping highest
possible feed rate.
 AC with constrains (ACC)
 For example, to maximize the machining feed rate while maintaining a constant
load on the cutter, despite variations in width and depth of cut.

 In a normal CNC system, the feed rate is programmed to accommodate the largest
width and depth in a particular cut, and this small feed rate is maintained along the
entire cut. As a result the machining rate is reduced.

 By contrast, with the ACC system, the maximum allowable load

(e.g., cutting force) on the cutter is programmed.

 As a result, when the width or depth of cut are small the feedrate is high; when either
the width or depth of cut (or both) are increased,
the feedrate is automatically reduced, and consequently the allowable load on the
cutter is not exceeded.

 The result is, the average feed with ACC is much larger than its programmed
counterpart.
 AC with optimization (ACO)
ACO refers to systems in which the performance is
optimized according to a prescribed IP(Index of
Performance), sometimes called the figure of merit.

The ACO Systems for N/C machine tools is a control

system that optimizes performance index subjects
to various constraints. It is basically a sophisticated
closed loop control system, which automatically
works in optimum conditions
 AC with optimization (ACO)
The input of the adaptive controller is the data
reduction Subsystem (DRS). This unit is fed by the
online measurement as well as by the actual feed and
speed and a set of constraints. The DRS produces two
signals:

Tool wear Rate (TWR)

 Metal Removal Rate (MRR).

 AC with optimization (ACO)
The TWR and MRR signals are fed in to a
performances computer unit which calculates the
performance index based on various factors such as
cost of the tool, cost of the machine, etc.

The calculated IP is fed into an optimization

computer unit (OCU), which contains the strategy
according to which the optimization is made.
 AC with optimization (ACO)
The main problem is that this require on-line measurement of
tool wear.
So far there have been no industrially acceptable
methods developed for the direct measurement of tool wear.
Indirect measurement assumes that tool wear is proportional to
other measurable variables such as cutting forces and
temperatures.
 The drawback of using these indirect measurements
is that variations in their values can be caused by process
variations other than tool wear, such as workpiece hardness or
cutting conditions.
Thus making it difficult to identify the tool wear effect from the
effect of the other parameter variations on the measurements.
 WHERE TO USE ADAPTIVE CONTROL
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) The in process time consumes a significant portion of machining
cycle time.
3) The cost of operating the machine tool is high.
4) The typical jobs involving steel, titanium and high strength alloys.
Cast iron and aluminum are attractive candidates for AC, but these
materials are generally easier to machine.
5) 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.
WHERE TO USE ADAPTIVE CONTROL
6) 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.

7) 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.

8) Air gaps during cutting

 ADVANTAGES OF AC SYSTEMS
Increased production rates.

Increased tool life.

Increased accuracy by making tolerance as a constraint.

Maximum component safety.

Minimum operator intervention.

Easy part programming.

 LIMITATIONS OF AC SYSTEMS

The lack of a tool wear sensor is the major obstacle to

the employment of ACO systems.

Unavailability of standardized interfaces of an AC

system with CNC units.