SUPPRESSION OF CUTTING FORCES USING COMBINED INVERSE MODEL BASED DISTURBANCE OBSERVER AND DISTURBANCE FORCE OBSERVER
Abstract
This paper focuses on damping strategies that addressed the effect that high frequency harmonics content of cutting force have on positioning accuracy of the x-axis of an XY positioning table via controller and observer design approaches. Cutting force generated from direct contact between the workpiece and cutting tool becomes input disturbance to the drive system of the positioning table. The force high frequency components if left undamped would generate vibration to the system thus affecting the system positioning accuracy, surface finish quality as well as tool life. For this purpose, a cascade P/PI position controller, an Inverse Model Based Disturbance Observer (IMBDO) and a Disturbance Force Observer (DFO) were designed and numerically analysed. The cascade P/PI controller was designed using traditional loop shaping frequency domain method. IMBDO estimates the input disturbance and any unmodelled system dynamics while DFO performs direct estimation of the cutting force using knowledge of harmonic frequencies corresponding to the input cutting force. A combined cascade P/PI controller with IMBDO and DFO reduced additional 3.83% and
1.90% tracking errors compared to separate application of IMBDO and DFO. This novel control approach produced between 34-80% greater reductions in peak amplitudes of the harmonics content of the cutting forces compared to cascade P/PI.Downloads
References
G. Ellis, Observers in Control Systems: A Practical Guide. USA: Academic Press, 2002.
T. Umeno and Y. Hori, “Robust speed control of DC servomotors using modern two degrees-of freedom controller design,” IEEE Transactions on Industrial Electronics, vol. 38, no. 5, pp. 363–368, 1991.
Y. Hori and K. Shimura, “Position/force Control of multi-axis robot manipulator based on the TDOF robust servo controller for each joint,” in Proceedings of the American Control Conference, Chicago, Illinois, 1992, pp. 753–757.
K. Ohnishi and T. Murakami, “Advanced motion control in robotics,” in 15th Annual Conference of IEEE Industrial Electronics Society, Philadelphia, USA, 1989, pp. 356-359.
S. Huang, K. Tan, G. S. Hong, and Y. S. Wong, “Cutting force control of milling machine,” Mechatronics, vol. 17, no. 10, pp. 533-541, 2007.
Z. Jamaludin, H. V. Brussel, G. Pipeleers, and J. Swevers, “Accurate motion control of XY high-speed linear drives using friction model feedforward and cutting forces estimation”, CIRP Annals-Manufacturing Technology, vol. 57, no. 1, pp. 403-406, 2009.
Z. Jamaludin, J. Jamaludin, T. H. Chiew, L. Abdullah, N. A. Rafan, and M. Maharof, “Sustainable cutting process for milling operation using disturbance observer”, Procedia CIRP, vol. 40, pp. 486-491, 2016.
J. G. Njiri, B.W. Ikua, and G. N. Nyakoe, “Cutting force control for ball end milling of sculptured surfaces using fuzzy logic controller”, Journal of Scientific Conference Proceedings, pp. 249-255, 2012.
A. Suebsomran and M. Parnichakun, “Disturbance observer-based hybrid control of displacement and force in medical tele-analyzer for abdominal mass analysis,” in Industrial Technology, IEEE International Conference, Bangkok, Thailand, 2002, pp. 365-369.
F. Mobasser and K. Hashtrudi-Zaad, “A model-independent force observer for teleoperation systems,” in Mechatronics and Automation, IEEE International Conference, Niagara Falls, Canada, 2005, pp. 964- 969.
L. Abdullah, Z. Jamaludin, T. H. Chiew, N. A. Rafan, and M. S. Syed Mohamed. “System identification of XY table ballscrew drive using parametric and non-parametric frequency domain estimation via deterministic approach,” Procedia Engineering, vol. 41, pp. 567-574, 2012.
R. Pintelon and J. Schoukens, System Identification: A Frequency Domain Approach. New Jersey: John Wiley & Sons, 2012.
M. H. Abu Bakar, R. A. Raja Izamshah and M. M. A. Amran,”Machining model of TI-6AL-4V titanium alloy using FEM simulation”, Journal of Advanced Manufacturing Technology, vol. 6, no. 2, pp. 1-9, 2012.
C. J. Kempf and S. Kobayashi, “Disturbance observer and feedforward design for a high-speed direct drive positioning table”, IEEE Transactions on Control System Technology, vol. 7, no. 5, pp. 513-526, 1999.
Authors who publish with this journal agree to the following terms:
- Authors transfer copyright to the publisher as part of a journal publishing agreement with the work simultaneously licensed under a Creative Commons Attribution License that allows others to share the work with an acknowledgement of the work's authorship and initial publication in this journal.
- Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the journal's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgement of its initial publication in this journal.
- Authors are permitted and encouraged to post their work online (e.g., in institutional repositories or on their website) after the manuscript is accepted, as it can lead to productive exchanges, as well as earlier and greater citation of published work (See The Effect of Open Access).