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A Thesis on DEVELOPMENT OF SIMULATION FOR AN ADAPTIVE CONTROL MACHINING SYSTEM

ABSTRACT
In any machining process the economic objective is to maximize the metal removal rate by the highest possible feed rate under the constraint of tool breakage. An NC Program merely guides and controls a Machining process. It cannot respond and react to variations in machining conditions during the operation. This results in many unfavorable situations like greater lead times, tool damage, extreme caution in work handling etc. during machining. Machining force regulation and tool wear are challenging problems since the force and temperature rise varies significantly under normal operating conditions. In order to overcome above mentioned problems, the concept of ADAPTIVE CONTROL MACHINING was introduced. The purpose of

introducing this concept is to control and optimize the variable cutting parameters. The main aim of Adaptive Control Machining (ACM) is: 1. Improve the process productivity 2. Reduce the operational costs 3. Reduce the machining lead times Adaptive Control system (AC) maximises material removal rates and minimises cycle times by optimising the cutting feed rate based on a controlled spindle load. The applications of ACM are not only limited to NC machining but such systems are designed to compensate for environment changes perceived, monitored, altered or reset according to the situation In the current project undertaken, we have elucidated and applied the Adaptive Control principles to TURNING. As a part of this work, we have conducted experiments on a LATHE machine. The specimens selected for this experiment are specially designed so that the required sources of variability are included. In accordance to the results obtained, the application of Adaptive control principles to TURNING is aptly justified. As part of this work, a simulation is developed for turning process based on adaptively controlled experimental data. TABLE OF CONTENTS

CHAPTER I:

INTRODUCTION

1.1 Basics of adaptive control 1.2 Structure of adaptive control 1.3 Classification of Adaptive control system 1.4 Sources of variability 1.5 Need for adaptive control 1.6 Applications of adaptive control

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CHAPTER II: LITERATURE REVIEW 2.1 Introduction 2.2 Brief discussion 2.3 Cutting constraints 2.4 Proportionality gain constant for EN8 2.5 Proportionality gain constant for EN24 2.6 Summary 14 15 17 18 21 24

CHAPTER III: PROBLEM DEFINITION 3.1 Generation of experimental data 3.1.1 Simulation 3.2 Experimental setup 3.3 Sensing equipment in experimental work 3.4 Dynamometers and thermocouples 3.5 Material selection 25 26 27 28 29 30

CHAPTER IV: METHODOLOGY

ILLUSTRATION OF THE PROPOSED

4.1 Theoretical relations 4.2 Experimental procedure CHAPTER V: RESULTS AND DISCUSSIONS 5.1 Graphical representation 5.2 Inferential data CHAPTER VI: CONCLUSIONS & SCOPE FOR FUTURE STUDY APPENDIX: About the simulation software REFERENCES & BIBLIOGRAPHY

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CHAPTER I: INTRODUCTION TO ADAPTIVE CONTROL MACHINING (ACM) 1.1 INTRODUCTION

While CNC technology coupled with CAD/CAM has long helped to introduce flexibility in batch production, there still remains some major inefficiency inherent in most machining processes. Present day CNC technology relies on the programmers' input of appropriate cutting parameters - even when sophisticated software systems are used to generate NC programs. The fact is that NC programming is based on predetermined and unchanged conditions. The control mechanisms of CNC machines are limited to geometry and kinematics. As such, they follow pre-programmed and constant speed and feed rates during each cutting segment. Consequently, they do not have the flexibility required for adapting to the dynamic changes that occur during cutting. This inflexibility would be acceptable if cutting conditions were uniform during machining. In practice, however, cutting conditions tend to

continuously vary for many of the following reasons:

Uneven work piece surface.

Gradual tool wear.

Material hardness varies within each work piece.

Work piece dimensions vary from piece to piece.

Temperature variations in material during cutting.

The fixture's stability may be affected during cutting.

NC programs may contain errors.

Advances in CAD/CAM technology have caused machinists to focus most of their attention to "defining the required geometry" and ignore the need to consider the rest of the previously mentioned conditions. However, with all of the those deviations in mind, NC programmers have no alternative but to be conservative in determining cutting parameters - resulting in safer but more inefficient cutting processes. No matter how optimized NC programs may be, they cannot take into account these dynamic variations encountered during cutting. At best, long NC programs may be created with different feed rates for each segment. However, these programs still cannot modify cutting parameters in real time in order to adapt to unexpected conditions that may occur during cutting.

Adaptive control systems ensure automatic optimization of the machining process to reduce cycle times, increase tool utilization and prevent tool breakage, thus lowering machining costs and increasing machine capacity. These adaptive control systems are applicable on CNC milling, turning and drilling applications. Typical applications include rough milling when the material and work piece surface hardness vary, die and mold manufacturing, blade manufacturing and helical milling on turning centers. Machining cycle times are typically reduced by 10 to 40 percent, depending upon the application. Feed rate optimization algorithms use geometry and force models to calculate Feed rates for each tool move, based on a reference peak force. The adaptive controller adjusts the feed rate during machining to maintain the reference peak force. It is the combination of these methods that yields accurate force control, unobtainable with either method by itself.

Adaptive control alone is inadequate to handle significant transient cut conditions because of the slow system response time. Design parameters for the adaptive controllers are selected using an experimentally validated machining process model.

Experimental results demonstrate the ability of the integrated system to effectively regulate peak forces for cutting conditions commonly encountered in end milling operations. The focus of this research is peak force regulation in 3-axis machining through the use of optimized feed rates and adaptive force control. Our current feed rate optimization program is effective in force regulation but it is subject to inaccuracies caused by errors in the force prediction model. These inaccuracies can result in high peak forces during machining, leading to unacceptable dimensional errors or surface finish. On the other hand, if the peak forces are too low, the machining efficiency is reduced. An on-line adaptive controller is proposed to compensate for these inaccuracies, providing accurate regulation of the reference peak force. Force control algorithms have been developed and evaluated by numerous researchers.

1.2

STRUCTURE

OF

ADAPTIVE

CONTROL

SYSTEM:
For a machining operation, the term adaptive control denotes a control system that measures certain output process variables and uses these to control speed and feed.

In short, if there are any deviations in the properties and behavior of work materials and tools, adaptive control system converts a lifeless machine into a self-thinking and self acting machine. During the past decade the part programmer has to mention the operating parameters like feed, speed, depth of cut basing on his knowledge and experience. Moreover, increasing complexities in work pieces material, tool material and cutting conditions have made optimized selection of spindle speed and feed rate practically impossible. In order to overcome such problems, adaptive control systems are used for controlling and optimizing variable cutting parameters.

1.3:

CLASSIFICATION

OF

ADAPTIVE

CONTROL

SYSTEM Adaptive control employs automatic on-line adjustment of the parameters for optimizing the performance of machining systems. Adaptive controllers are of three types Adaptive control with Constraint (ACC) Adaptive control with Optimization (ACO) Combination of (1) & (2)

1.3.1Adaptive control with optimization: In this form AC, an index of performance is specified for the system. This performance index should be a measure of overall process performance such as production rate or cost per volume of metal removed. The objective of this AC is to optimize the index of performance by manipulating speed or feed in the operation.

1.3.2Adaptive control with constraint: It regulates cutting parameters to maintain a resultant parameter such as cutting force, spindle power or tool tip

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temperature which allows power capacity of machine to be fully utilized. 1.4 SOURCES OF VARIABILITIES: The flexibility of any system depends upon the hindrances which affect its performance. Similarly, there are some variables which affect a machining process. In this section, we shall consider various sources of variations in a machining process. They are summarized below along with probable solutions to them.

Uneven work piece surface. Gradual tool wear. Material hardness varies within each work piece. Work piece dimensions vary from piece to piece. Temperature variations in material during cutting. The fixture's stability may be affected during cutting. NC programs may contain errors. Spindle deflection

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1.5 NEED FOR ADAPTIVE CONTROL SYSTEM: Increasing complexities in cutting conditions have made optimized selection of spindle speed and feed rate practically impossible. To ensure the quality of machined products. To reduce the machining costs and increase the machining efficiency. To satisfy optimal machining criteria, some form of on line control system is required by which performance is monitored and the machine conditions are adjusted according to the results obtained. In order to overcome above mentioned problems, the concept of

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ADAPTIVE CONTROL MACHINING

was introduced. In automatic

adaptive control, a set of sensors continuously measures performance and a computer combines these inputs with assumed weighting factors and adjusts the m/c to approach optimum performance after each set of inputs. 1.6 ADVANTAGES AND APPLICATIONS OF ADAPTIVE CONTROL(AC) SYSTEMS:

Increase production rates Increased tool life Greater part protection Less operator intervention Easier part programming
AC can deal with the following situations

Material and tool characteristic variations within their own


specification

Variations of depth of cut(e.g., forgings and castings) Machinability variations within the work piece Variations in machine tool behavior with time

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250 260 270 280 290 300

26.03 30.44 36.21 38.32 40.33 43.33

35 36 38 36 34 34

15 16 16 16 15 14

15 15 12 13 12 12

40.92 42.15 42.94 41.48 39.05 38.67

100 109 118 125 123 126

80 80 80 80 80 80

45 45 45 45 45 45

Simulation for case 9:

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CHAPTER V RESULTS AND DISSCUSIONS

In case of plain turning with ACC for EN8 it is observed that 39% of machining time is saved, time taken to stabilize the force is 19.44 seconds and the optimum force utilized is 37 Kgf.

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In case of plain turning with ACC for EN24 it is observed that 32% of machining time is saved, time taken to stabilize the force is 26 seconds and the optimum force utilized is 41 Kgf. As compared to EN8 optimum force utilization is more because of its higher hardness number.

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In case of step turning with ACC for EN8 it is observed that 34% of machining time is saved, time taken to stabilize the force is 24 seconds and the optimum force utilized is 38 Kgf.

In case of step turning with ACC for EN24 it is observed that 33% of machining time is saved, time taken to stabilize the force is 30

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seconds and the optimum force utilized is 43 Kgf. In case of step turning optimum force utilization is more and time saving is less because of reduced feed rate to compensate increase in depth of cut.

In case of plain turning with airgap for EN 8 it is observed that 42% of machining time is saved, time taken to stabilize the force is 18 Sec and the optimum force utilized is 40Kgf.

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In case of plain turning with airgap for EN 24 it is observed that 40% of machining time is saved, time taken to stabilize the force is 19 seconds and the optimum force utilized is 40Kgf. In case of plain turning with airgap percentage of time saving is more during airgap tool moves at maximum feed rate.

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In case of plain turning with ACC for EN24 it is observed that 30% of machining time is saved, time taken to stabilize the force is 30 seconds and the optimum force utilized is 45Kgf. From this graph we can understand that temperature rise is more during first half and less during remaining half and it is proportional to 0.8 power of the feed.

In case of plain turning with airgap for EN24 it is observed that 45% of machining time is saved, time taken to stabilize the force is 35 seconds and the optimum force utilized is 46Kgf. In this case temperature drop is more during airgap and temperature rise is less compared to plain turning.

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In case of turning with fillet, airgap, taper turning for EN24 it is observed that 30% of machining time is saved, time taken to stabilize the force is 26 seconds and the optimum force utilized is 40Kgf. Machining time saved is less. During taper turning feed is reduced continuously to compensate continuous increase in depth of cut. From this we have observed that 30% of tool life is increased due to constraints imposed on cutting force and temperature rise. 40% of machining time is saved by applying ACC principles to turning process.

CHAPTER VI CONCLUSION & SCOPE FOR FUTURE STUDY We conclude from the above that the results are improved when we apply adaptive control principals in machining process. Keeping in mind, the present day manufacturing scenario it is of

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prime importance that the manufacturing process we use, should not lead to problems. This is kept under surveillance by the

introduction of adaptive control machining. The use of controller is a must in adaptive control systems. However, taking into

account the immense expenditure incurred due to its installation, we have carried out the same on a conventional machining system. Fierce competition in international manufactured products has resulted in rapid growth in the use of computer controlled machine tools. Productivity gain during manufacturing and

particularly in machining With minimum modification in machine control system, it maximizes use of existing controller hardware Tests show that using ac system substantially 40% saving in machining time are occurring with nominal expenditure on extra hardware. According to this work, it is obvious that the application of adaptive control principles is fruitful. Simulation of turning

process for various conditions is very useful in understanding the machining process.

SCOPE FOR FUTURE STUDY: This work can be extended further. The methodology we had proposed can be effectively applied to other machining processes like milling, drilling, shaping etc.

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Appendix 3Dimensional studio max (3Dsmax9):

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This is the product of AutoDesk developed in 1990.. This software is ideal to create any object and to apply any textures to bring reality to any object in 3D world. This software is very popular for creating walk through, materials and virtual reality in space simulations, tool design etc. It is extensively used in Architectural engineering animation industries. In India; it is extensively used in animation as well as in engineering industry.

Applications:
It can create any object in 3D world and can export any file format especially for web (.JPG, .PNG, .AVI etc.). Video formats for animation industry and simulation and can export dwf formats, which can be viewed in any windows applications with interactivity. It is so popular because it is very easy to understand its views, textures and can render objects very quickly without large usage of memory. It can bring about realistic effects in a computer simulation when compared with other 3D soft wares like Bryce 3D, Cinema 4D etc. The special effects in some popular movies like The Independence Day in 1994, Crazy frog in 2005 etc. are created using this software. It is very ideal to create 3D environment and texturing in gaming industry as well.

Steps:
1. Create a cylinder in front view port and set its length to 300 units.

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2. Take the copy of same cylinder and reduce its length to 20 units and increase its radius to 5 units. 3. Take a box in top view and convert into editable mesh. Adjust its coordinates to bring it a tool shape. Now we have a tool, chuck, and work piece. 4. Now animate the tool by setting auto key. Drag the slider to 100th frame. Translate the tool in y-direction up to 10 points. 5. In this way animate the tool in x-direction at required intervals in required positions. 6. In the same way animate the height of the work piece in accordance with the tool at required intervals in required positions. 7. Save the scene. Set the view render the complete animation up to required frames and convert it into a .AVI file which can be played in any system.

Flash (MX):
Flash is a product of Macromedia which has its applications developed for web (www) in 1993. Flash is popular software for creating 2D animation, web animations, websites, presentations, intros etc. The software is popular among 2D animations and game designs. The flexibility in the tools enables the user for vector

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drawing in computers. The interactivity in action scripting made flash the very popular subject in gaming industry. This is very ideal for creating web graphics and animations. Because its a vector-based programme, it requires less time to download when compared with other GIF animations, which is very essential in web. This is made flash a very popular subject for web animators and web designers. It can readily import any file formats like .JPEG, .PNG, .GIF, .AVI, .MOV, .MP3 etc. and can export file formats required for web and video such as .JPG, .GIF, .PNG, .AVI, .SWF, .EXE, .HTML, .SPLASH etc.

Steps:
1. Take a file of size 800*600. 2. Go to file import and browse the simulation that we have created using 3D Max earlier, which is in .AVI format. 3. Now create buttons from symbols to create interactivity with simulation by using action scripting. 4. In flash, its very easy to add text and interact with the animation. It can readily export any type of file format such as .EXE, with interactivity, which is very essential.

REFERENCES / BIBLIOGRAPHY
1. Selection of machining parameters for constrained machining problem using evolutionary computation

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(International Journal of Advanced Manufacturing Technology2006) 2. Optimization of machining parameters for milling operations using non-conventional methods.(Int.Journal of Adv Manuf. Technology). 3. Design and implementation for maximum metal removal rate control of a constant turning force system.(Int Journal of Materials Processing Technology). 4. Adaptive turning force control with optimal robustness and constrained Manufacture) . 5. Feed rate optimization for variant milling process based on cutting force prediction (Int. Journal of Adv. Manufacturing Technology.) 6. Model based machining force control(Int.Journal of Dynamic Systems, Measurement And Control ASME) 7. Adaptive control constraint of machining processes(Int. Journal of Advanced Manufacturing Technology) 8. Principals of automation and advanced manufacturing systems by Dr. K.C. Jain and Sanjay Jain, Khanna Publishers. feed rate.(Int. Journal of Machine Tools

9. Computer Aided Design and Manufacturing by Dr. Sadhu Singh, Khanna Publishers. 10. Computer Aided Design and Manufacturing by Dr. Sadhu Singh, Khanna Publishers.

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11. CAD / CAM by Mikell P. Groover and Emori W. Zimmers Prentice Hall Publishers. 12. Material Science and Metallurgy by V. D. Kodgari Everest Publishing House. 13. Automatic production systems and computer integrated manufacturing by Mikell P. Groover, Prentice Hall Publishers. 14. Computers numerical control machining by Yorrem Koren. 15. CAD / CAM principles & applications, by P.N. Rao, TMH publications.

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