Cutting Force-Based Feedback Control Scheme for Surface Finish Improvement in Diamond Turning

The control of diamond turning is usually achieved through a laser-interferometer feedback of slide position. The limitation of this control scheme is that the feedback signal does not account for additional dynamics of the tool post and the material removal process. If the tool post is rigid and the material removal process is relatively static, then such a non-collocated position feedback control scheme may suffice. However, as the accuracy requirement gets tighter and the desired surface contours become more complex, the need for a direct tool-tip sensing becomes inevitable. The physical constraints of the machining process prohibit any reasonable implementation of a tool-tip motion measurement. It is proposed that the measured force normal to the face of the workpiece can be filtered through an appropriate admittance transfer function to result in the estimated depth of cut. This can be compared to the desired depth of cut to generate the adjustment control action in addition to position feedback control. In this work, the design methodology on the admittance modelbased control with a conventional controller is presented. Based on the empirical data of the cutting dynamics, simulation results are shown. In addition, the recursive least-squares algorithm with forgetting factor is proposed to identify the parameters and update the admittance model in real time.