Surface roughness control simulation of turning processes

Abstract

The aim of this paper is to present a surface roughness control in turning with an associated simulation block diagram. The objective of the new model based controller is to assure the desired surface roughness by adjusting the machining parameters and maintaining a constant cutting force. It modifies the feed rate on-line to keep the surface roughness constant and to make machining more efficient. The control model was developed based on simplified models of the turning process and the feed drive servo-system. The experiments were performed to find the correlation between surface roughness and cutting forces in turning and to provide functional correlation with the controllable factors. Simulation setup and results are presented to demonstrate the efficiency of the proposed control model. In terms of surface roughness fluctuations and cutting efficiency, the suggested control model is much better than a conventional CNC controller alone. Integrating the developed control model with the CNC machine controller significantly improves the quality of machined components.