Machining process as a subject of automatic control

This report deals with the analysis and the design of a conventional machining system by means of mathematical modeling of the machining process. The paper considers the machining process as a dynamic interaction between the cutting tool and workpiece in space and time that additionally involves the dynamic properties of the machine tool mechanical subsystem, the cutting process, and the cutting motions. An ideal machining system provides an accurately controlled tool path. However, machining experience has shown that the geometric qualities of the machined part are not only defined by the uniformity of the tool path, but are also influenced by the dynamics of the machine tool and cutting process and by the external and internal disturbances. Developed herein, is a systematic approach tying together the four main factors associated with the dynamic processes that play an important role during machining and influence the quality of the machined workpiece. These factors are (a) the kinematic/dynamic disturbances within the cutting/feed motion subsystem, (b) the dynamics of the machine tool mechanical subsystem, (c) the tool-workpiece interaction as a dynamic process, and (d) the forming of the workpiece surface as a dynamic process. The generalized mathematical model of the machining process is developed based on the dynamic relationships between those above-mentioned aspects of the process. The approach performs the dynamic analysis of a machining process for diagnostics, control, and process optimization purposes.