Adaptive Cutting Force Control with a Hybrid Axis System

Cutting forces have a major effect on the results of a machining process. High loads on the tool can lead to surface geometry and surface roughness that are less than optimal. However, due to its high implementation costs, cutting force control is not often used on milling machines. The paper presents a new approach by integrating a hybrid axis system in the force control loop. This offers a more dynamic and accurate way to influence cutting forces, but it also results in a more complex control problem. Therefore, how the nonlinear and time-varying characteristics of the cutting process can be modeled and considered for an automated operation is comprehensively shown. The interaction of process estimation and control is demonstrated with a PID-Control structure. Experimental results are presented.