Adaptive Control Strategy for Cutting Force Compensation in Machine Tools

Chin, Seong Zheng (2025) Adaptive Control Strategy for Cutting Force Compensation in Machine Tools. Final Year Project (Bachelor), Tunku Abdul Rahman University of Management and Technology.

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Abstract

This study proposes an adaptive nonlinear PID (NPID) control strategy for compensating cutting force disturbances in CNC milling systems using MATLAB simulations. The aim is to improve the tracking accuracy and stability of a ball screw drive positioning system affected by dynamic disturbances. Three controller architectures PID, Cascade, and Adaptive NPID were designed, implemented, and evaluated. The performance of each controller was assessed through root mean square error (RMSE) and frequency analysis using Fast Fourier Transform (FFT) under various spindle speeds (0, 1000, 1500, and 2000 rpm). The results reveal that the Adaptive NPID controller exhibits the best tracking performance and superior disturbance rejection compared to conventional PID and cascade control systems, particularly at higher cutting forces. This research highlights the effectiveness of adaptive control strategies in precision machining and their potential for integration into Industry 4.0 smart manufacturing systems.