Home   >   CSC-OpenAccess Library   >    Manuscript Information
Active Control of Tool Position in the Presence of Nonlinear Cutting Forces in Orthogonal Cutting
A.H. El-Sinawi
Pages - 157 - 172     |    Revised - 01-07-2011     |    Published - 05-08-2011
Volume - 2   Issue - 3    |    Publication Date - July / August 2011  Table of Contents
MORE INFORMATION
KEYWORDS
LQG, Nonlinear ARX Model, Active Control, Orthogonal Cutting, Nonlinear Cutting Force
ABSTRACT
This work presents a practical approach to the control of tool’s position, in orthogonal cutting, in the presence nonlinear dynamic cutting forces. The controller is Linear Quadratic Gaussian (LQG) type constructed from an augmented model of both, tool-actuator dynamics, and a nonlinear dynamic model relating tool displacement to cutting forces. The latter model is obtained using black-box system identification of experimental orthogonal cutting data in which tool displacement is the input and cutting force is the output. The controller is evaluated and its performance is demonstrated.
1 Google Scholar 
2 CiteSeerX 
3 refSeek 
4 Scribd 
5 SlideShare 
6 PdfSR 
. A.H. El-Sinawi, A. H., and A. R. Kashani. “Improving surface roughness in turning using a Kalman estimator-based feed forward control of tools position”. Journal of Materials Processing Technology. 2005, 167, pp 54-61.
. A.H. El-Sinawi. “Two-dimensional vibration suppression in turning using optimal control of the cutting tool”. Int. J. Machining and Machinability of Materials. 2008, Vol. 3, Nos.1/2, 91-103.
. A.H. El-Sinawi. “Vibration attenuation of a flexible beam mounted on a rotating compliant hub”. Journal of Systems and Control Engineering, Part I, April, 2004, 218, pp 121-135.
. A.M. Shawky and M. A. Elbestawi. “An Enhanced Dynamic Model in Turning Including the Effects of Ploughing Force”. J. of Manufacturing Science and Engineering, 119:10-20,1997.
. Bernard W. Ikua, Hisataka Tanaka, Fumio Obata, Satoshi Sakamoto. “Prediction of cutting forces and machining error in ball end milling of curved surfaces -I theoretical analysis”. Precision Engineering, 25(4): 266-273, 2001.
. G.B. Boothroyd and W. A. Knight. Fundamentals of Machining and Machine Tools,Marcel Dekker, Inc., New York, 1989.
. Hamed Moradi, M.R. Movahhedy, G. Reza Vossoughi. “Robust control strategy for suppression of regenerative chatter in turning”. Journal of Manufacturing Processes.(2009) , 11, 55_65
. J. Peters and P. Vanherck. “Machine Tool Stability Tests and the Incremental Stiffness”.Annals of the CIRP, 17:225-232, 1969.
. K.A. Risbood, U.S. Dixit, A.D. Sahasrabudhe, Prediction of surface roughness and dimensional deviation by measuring cutting forces and vibrations in turning process.Journal of Materials Processing Technology 132, 203–214, 2003.
. K.F. Ehmann, S. G. Kapoor, R. E. DeVor, and I. Lazoglu. “Machine Process Modeling Review”. Journal of Manufacturing Science and Engineering, 119:655-663, 1997
. L. Kops, M. Gould, and M. Mizrach. “ Improved Analysis of the Workpiece Accuracy in Turning Based on the Emerging Diameter”. J. of Engineering for Industry, 115:253-257,1993.
. L. Ljung. System Identification: Theory for the User. Prentice Hall; 2nd edition, 1999
. L.K. Daneshmend and H. A. Pak. “Model Reference Adaptive Control of Feed Force in Turning”. J. of Dynamic Systems, Measurements and Control, 108:215-222, 1986
. M. Farina and L. Piroddi. “An iterative algorithm for simulation error based identification of polynomial input-output models using multi-step prediction”. International Journal of Control, 83, Issue 7 July 2010 , 1442 – 1456.
. M. Sander. A Practical Guide to the Assessment of Surface texture. Mahr Perthen,Gottingen, Germany, 1991.
. M. Shiraishi and H. Sumiya. “Improvement of Geometrical Errors by Surface Roughness and Tool Position Control”. The Annual Meeting of the ASME, PED-vol. 45:9-22, 1990.
. M.A. El Baradie. “Statistical Analysis of the Dynamic Cutting Coefficients and Machine Tool Stability”. J. of Engineering for Industry, 115:205-214, 1993.
. M.U. Jen and E. B. Magrab. “The Dynamic Interactive of the Cutting Process, Workpiece,and Lathe’s Structure in Facing”. J. of Manufacturing Science and Engineering, 118:348-357, 1998.
. N.H. Hanna and S. A. Tobias. “A Theory of Nonlinear Regenerative Chatter”. J. of Engineering for Industry, 96:247-253, 1974.
. O.B. Abouelatta, J. Madl, Surface roughness prediction based on cutting parameters and tool vibrations in turning operations, J. Mater. Process. Technol. 118, 269–277, 2001.
. P. Albrecht. “Dynamics of the Metal Cutting Process”. J. of Engineering for Industry.87:429-441, 1965.
. S. Fu, B. Muralikrishnan, and J. Raja, Engineering Surface Analysis with Different Wavelet Bases. Transactions of the ASME, 125, 844-852, 2003.
. S. M. Pandit and M. S. Shunmugan. “Signature of Machine Tool Errors on Surface Texture”. Annals of the CIRP, PED-Vol. 45:63-74, 1990.
. S.M. Pandit, T.L. Subramanian, and S.M. Wu. “Modelling Machine Tool Chatter by Time Series”. J. of Engineering for Industry, 97:211-215, 1975.
. S.N. Huang, K.K. Tan, Y.S. Wong, C.W. de Silva, H.L. Goh, W.W. Tan. “Tool wear detection and fault diagnosis based on cutting force Monitoring”. International Journal of Machine Tools & Manufacture. 2007, 47, 444–451
. T.E. Bailey, D.M. Jenkins, A.D. Spence, and M.A. Elbestawi, “Integrated Modelling for Metal Removal Operations”. Proc. Of the ASME Dynamic Systems and Control Division,58:191-198, 1996.
. W. Gawronsky. Advanced Structural Dynamics and Active Control of Structures.Springer-Verlag, 2004.
. W.S. Lin, B.Y. Lee, C.L. Wu, Modeling the surface roughness and cutting force for turning, Journal of Materials Processing Technology. 108, 286–293, 2001.
. Y. Altintas, M. Eynian, H. Onozuka. “Identification of dynamic cutting force coefficients and chatter stability with process damping”. CIRP Annals - Manufacturing Technology,2008, 57, 371–374.
. Y. Tian, B. Shirinzadeh, D. Zhang. “A flexure-based mechanism and control methodology for ultra-precision turning operation”. Precision Engineering. 2009, 33, 160–166
. Y. Zhu. “Estimation of an N-L-N Hammerstein-Wiener Model”. Automatica. 2002, 38,1607-1614.
Associate Professor A.H. El-Sinawi
American University of Sharjah - United Arab Emirates
aelsinawi@aus.edu