Comparison of experimental results obtained by designed dynamometer to fuzzy model for predicting cutting forces in turning

This paper presents a comparison of experimental results and consistent fuzzy rule-based model for estimating the cutting forces in turning. A dynamometer that can measure static and dynamic cutting forces by using strain gauge and piezo-electric accelerometer, respectively, was used for measuring the forces. AISI 1040 steel was used as the workpiece material. Feed force, thrust force and main cutting force were measured for three combinations of cutting speeds, feedrates and depth of cuts. The rake angle and approach angle of the cutting tool were kept constant throughout the experiments. The fuzzy model consists of 27 rules. In this research, a Mamdani max–min inference for inference mechanism and the centre of gravity (Centroid) defuzzifier formula method for defuzzification were used as these operators assure a linear interpolation of the output between the rules. It has a wide range of applications over many types of steels and turning conditions. It is also simple to implement, from a rule-chart mode to an intelligent on-line adaptive control mode. Experimental results were compared with the predicted fuzzy model. The difference between experimental and predicted results was obtained as around 99.6%.