A model-based adaptive controller for chatter mitigation and productivity enhancement in CNC milling machines

•Model-based controller for milling process based on Optimal Control Theory.•Multi-objective optimization: vibrations, tool deflection, tool wear and productivity.•Real-time model of cutting process based on computation of tool-workpiece engagement.•Implementation and testing on a commercial milling machine by Alesamonti.

Seeking a higher level of automation, according to Intelligent Manufacturing paradigm, an optimal process control for milling process has been developed, aiming at optimizing a multi-objective target function defined in order to mitigate vibration level and surface quality, while preserving production times and decreasing tool wear rate. The control architecture relies on a real-time process model able to capture the most significant phenomena ongoing during the machining, such as cutting forces and tool vibration (both forced and self-excited). For a given tool path and workpiece material, an optimal sequence of feedrate and spindle speed is calculated both for the initial setup of the machining process and for the continuous, in-process adaptation of process parameters to changes the current machining behavior. For the first time in the literature, following a Model-Predictive-Control (MPC) approach, the controller is able to adapt its actions taking into account process and axes dynamics on the basis of Optimal Control theory. The developed controller has been implemented in a commercial CNC of a 3-axes milling machine manufactured by Alesamonti; the effectiveness of the approach is demonstrated on a real industrial application and the performance enhancement is evaluated and discussed.