Kuwait Journal of Science

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Volume :30 Issue : 2 2003      Add To Cart                                                                    Download

An adaptive control simulation approach based on a mathematical model optimization algorithm for rough turning.


Department of Mechanical Production Technology, College of Technological Studies,

PAAT, P.O.Box 42325, Shuwaikh 70654, Kuwait


Adaptive Control (AC) of machine tools is the latest and most sophisticated technology in today’s manufacturing processes. Its ultimate object is to increase productivity through the optimal utilization of cutting parameters under system constraints. However, there are still many technical difficulties delaying its practical implementation. Among these are the complexity and, sometimes, the inaccuracy of the measuring instrumentations, and the sluggishness of the system response.

In this paper, an optimization algorithm for adaptive control systems is described that is based on interactive time-varying mathematical models. The main objective of the developed routine is to build software in which the mutual functional interrelation between cutting parameters in longitudinal rough turning operations and their pertinent outputs is organized to achieve some objective functions. The developed routine can be linked to a conventional AC structure to maximize the metal removal rate while maintaining tool wear and cutting force within the pre-specified levels. This is achieved via the instantaneous selection of the appropriate cutting parameters that usually govern the quality of the system outputs, especially speed and feed.

Flex language syntax is used to integrate the developed mathematical models and optimization criteria to constitute the entire structure of the routine. Mathematical models are developed based on experimental data intended for a certain tool-work piece machine combination to cover a wide range of operating parameters that are usually used in rough turning. Objective criteria are specified considering system productivity and safety targets.

The developed algorithm has been tested in several runs considering different ranges of cutting speed. Numerical results support the feasibility and the significance of the proposed approach. At almost all speed levels, productivity is increased, especially at low to moderate levels that are usually used in practical rough turning operations and, fortunately, this is usually accompanied by the lowest wear rate.

Keywords: Adaptive control for machine tools; Cutting forces; Metal removal rate; Time-varying non-liner mathematical models; Tool wear and wear rate.

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