Progressive development of an absolute sensorless compensation system for cutting force-induced error

Cutting forces in traditional machining processes solely originates from the contact points on the cutting tool and workpiece. Therefore comprehensive mechanistic modeling of the machining process offers a means for realizing a sensorless cutting force monitoring system. This paper presents the progressive development of a sensorless compensation system for cutting force-induced error, whereby a learning and intelligent computer system is established, based on machining mechanics modeling and a reference compensation system. Experiences from normal machining sessions of new cutting tools and workpieces are modeled progressively and incorporated into the system. Finally with ample experience available, a full-fledged sensorless system is developed as a stand-alone solution. The sensorless system is economical, convenient, reliable and efficient. Administered on a CNC face milling machine, the model demonstrated exceptional performance and robustness.

[1]  Warren R. DeVries,et al.  A Mechanistic Dynamic Model of End Milling for Process Controller Simulation , 1991 .

[2]  Placid Mathew Ferreira,et al.  A method for estimating and compensating quasistatic errors of machine tools , 1993 .

[3]  Aun-Neow Poo,et al.  Error compensation in machine tools — a review: Part I: geometric, cutting-force induced and fixture-dependent errors , 2000 .

[4]  Jun Ni,et al.  Thermal error modeling for volumetric error compensation , 1992 .

[5]  Tae-Yong Kim,et al.  Adaptive cutting force control for a machining center by using indirect cutting force measurements , 1996 .

[6]  Masanori Ohori,et al.  Development of Concrete Machining Center and Identification of the Dynamic and the Thermal Structural Behavior , 1988 .

[7]  Soichi Ibaraki,et al.  326 Monitoring and Adaptive Control of Cutting Forces Based on Spindle Motor and Servo Motor Currents in Machining Centers , 2003 .

[8]  Robert D. Lorenz,et al.  General Methodologies for Neural Network Programming , 2002 .

[9]  Panos J. Antsaklis,et al.  Neural networks for control systems , 1990, IEEE Trans. Neural Networks.

[10]  Yoram Koren,et al.  Variable gain adaptive control system for turning , 1983 .

[11]  Anthony Chukwujekwu Okafor,et al.  Derivation of machine tool error models and error compensation procedure for three axes vertical machining center using rigid body kinematics , 2000 .

[12]  Peter J. Gawthrop,et al.  Neural networks for control systems - A survey , 1992, Autom..

[13]  Jun Ni,et al.  An On-Line Measurement Technique for Machine Volumetric Error Compensation , 1993 .

[14]  Richard E. DeVor,et al.  The prediction of cutting forces in end milling with application to cornering cuts , 1982 .

[15]  A. Galip Ulsoy,et al.  Principal Developments in the Adaptive Control of Machine Tools , 1983 .

[16]  Placid Mathew Ferreira,et al.  Kinematic modeling of quasistatic errors of three-axis machining centers , 1994 .