Design and implementation for maximum metal removal-rate control of a constant turning-force system

Abstract Operational parameters such as cutting depth, feed, and spindle speed, are regulated to satisfactory values by an adaptive controller with constraints (ACC) in order to bring the machine tool to its maximum productivity during the cutting process. When the cutting force is maintained by a constant turning force (CTF) controller, the spindle speed can be determined easily by specifying a cutting condition such as that of metal removal rate (MRR). In this paper, an auxiliary maximum MRR (MRR max ) controller on the CTF system, with a variable structure system (VSS) controller, can automatically manipulate the spindle speed to maintain the MRR at the specified suitable maximum-value. The design and implementation method are presented, and a series of simulations and experimental results, illustrating the reliable improvement over the CTF system, are given.