An adaptive fuzzy controller for constant cutting force in end-milling processes

A novel multilevel fuzzy control system is introduced and implemented for online force control of end-milling processes to increase machining productivity and improve workpiece quality, where the cutting force is maintained at its maximum allowable level in the presence of different variations inherent in milling processes, such as tool wear, workpiece geometry, and material properties. In the controller design, the fuzzy rules are generated heuristically without any mathematical model of the milling processes. An adaptation mechanism is embedded to tune the control parameters online, and the resultant closed-loop system is guaranteed to be stable based on the input-output passivity analysis. In the experiment, the control algorithm is implemented using a National Instrument real-time control computer in an open architecture control environment, where high metal removal rates are achieved and the cycle time is reduced by up to 34% over the case without any force controller and by 22% compared with the regular fuzzy logic controller, thereby indicating its effectiveness in improving productivity for actual machining processes.