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TECHNICAL PAPERS

Control of Cutting Force for Creep-Feed Grinding Processes Using a Multi-Level Fuzzy Controller

[+] Author and Article Information
Chengying Xu

School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907

Yung C. Shin1

School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907shin@ecn.purdue.edu

1

Corresponding author.

J. Dyn. Sys., Meas., Control 129(4), 480-492 (Sep 28, 2006) (13 pages) doi:10.1115/1.2718238 History: Received July 01, 2005; Revised September 28, 2006

In this paper, a multi-level fuzzy control (MLFC) technique is developed and implemented for a creep-feed grinding process. The grinding force is maintained at the maximum allowable level under varying depth of cut, so that the highest metal removal rate is achieved with a good workpiece surface quality. The control rules are generated heuristically without any analytical model of the grinding process. Based on the real-time force measurement, the control parameters are adapted automatically within a stable range. A National Instrument real-time control computer is implemented in an open architecture control system for the grinding machine. Experimental results show that the cycle time has been reduced by up to 25% over those without force control and by 10–20% compared with the conventional fuzzy logic controller, which indicates its effectiveness in improving the productivity of actual manufacturing processes. The effect of grinding wheel wear is also considered in the creep-feed grinding process, where the grinding force/power can be maintained around the specified value by the proposed MLFC controller as the wheel dulls gradually.

Copyright © 2007 by American Society of Mechanical Engineers
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Figures

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Figure 1

Multi-level fuzzy control (MLFC) system

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Figure 2

Fuzzy membership functions for inputs and output

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Figure 3

Controller interface for a CNC machine using digital communication

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Figure 4

Overall structure of the experimental setup

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Figure 5

Illustration of the creep-feed grinding process

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Figure 6

Force signals without force control

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Figure 7

Force signals, control signal, and output MFs with the regular FLC controller

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Figure 8

Force signals, control signal, and output MFs with the MLFC controller

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Figure 9

Illustration of the creep-feed grinding process

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Figure 10

Force signals without force control

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Figure 11

Force signals, control signal, and output MFs with the regular FLC controller

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Figure 12

Force signals, control signal, and output MFs with the MLFC controller

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Figure 13

Illustration of the creep-feed grinding process

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Figure 14

Force signals and control signal without the force controller

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Figure 15

Force signals and control signal with the MLFC controller

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Figure 16

Illustration of the wheel wear experiment

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Figure 17

Power signals and control signal without any controller

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Power signals and control signal with the MLFC controller

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Figure 19

Illustration of the wheel wear experiment

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Figure 20

Power signals and control signal without any controller

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Figure 21

Power signals and control signal with the MLFC controller

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