Adaptive control in high speed machining for improved surface finish

Abstract

This paper deals with development of an adaptive control system based on cutting speed correction algorithm to deliver consistent part quality in high speed machining (HSM). Rapid tool wear in HSM affects the part quality in terms of surface finish (Ra). Cutting force which is an indirect measure of surface finish is taken as input for the proposed adaptive control system. The adaptive control is implemented using the graphical programming language of LabVIEW. A process capability study is carried out with existing set-up and with adaptive control system. It was observed that, with a marginal increase in cutting speed, for a semi-dull tool, the resultant cutting force decreased and the surface finish improved. The process capability index and process capability ratio have shown 39% and 25% improvement respectively. The developed adaptive control system based on cutting speed will be an alternate to the existing feed rate correction algorithm.