Design and Analysis of Nonlinear Cascade Controller for Cutting Force Compensation of Machine Tools

Chong, Nocholas Lik Wen (2024) Design and Analysis of Nonlinear Cascade Controller for Cutting Force Compensation of Machine Tools. Final Year Project (Bachelor), Tunku Abdul Rahman University of Management and Technology.

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Abstract

In precision machining, controlling cutting forces is crucial for maintaining high product quality and extending the lifespan of machine tools. This study presents the design and analysis of a nonlinear cascade controller designed to compensate for the variations in cutting forces that occur during machining operations. The complexities of the machining environment, such as changes in material properties, tool wear, and external disturbances, are initially explored. The developed cascade control architecture incorporates dual control loops: an outer loop that sets the cutting force reference and an inner loop that quickly adjusts to changes, ensuring effective force compensation. The innovation of this study lies in the controller’s nonlinear design, which is crafted to adapt dynamically to the inherent nonlinearities of the machining process, promising a significant improvement over traditional linear control methods. Through rigorous analytical methods and simulation tests, the controller’s effectiveness is validated, highlighting its potential to enhance operational efficiency and product quality in machine tools. The findings suggest that advanced control strategies, like the one developed in this study, can play a vital role in advancing the capabilities of modern machining systems.