Online process control and self-configuration of turning operations

The surface roughness and the process efficiency may vary significantly in a turning process due to inevitable tool wear. Online process controls can therefore be employed in order to compensate for the influence of tool wear by adapting critical cutting parameters. In this study, the cutting parameters are adapted using a multiple-input, multiple-output controller to achieve reduced tool wear rates and high process efficiency while maintaining the surface roughness within defined limits. The measurement setup, controller design, self-configuration algorithm and a comparison of efficiencies of controlled and conventional machining are discussed.