Fuzzy control of spindle power in end milling processes

This paper reports a fuzzy control system for power regulation in end milling processes. This control system is capable of adjusting both feedrate and spindle speed simultaneously. Experiments have been carried out using both steel and aluminum workpieces of various cutting geometries. Different tools (HSS and carbide tools of different diameters and different number of teeth) have been used for aluminum workpieces. Both full immersion slotting and partial immersion cutting were tested. Our test results show that the system was in sensitive to workpiece and tool changes and cutting power was well regulated around the target levels for various types of variations in depth of cut. Our test results also show that as compared to single parameter (feedrate) adjustment, further savings in machining time can be achieved by adjusting both feedrate and spindle speed.