Disturbance Observer and Optimal Fuzzy Controller Used in Controlling of Cutting Force and Torque in High Performance of Drilling Process for Ferrous and Non-ferrous Industrial Materials

The automation of machining processes requires highly accurate process monitoring. However, the use of additional sensors leads to a significant increase in the cost and reduces the stiffness and reliability of mechanical systems. Hence, we propose a system called the cutting force and torque observer, which uses a sensor-less and real-time cutting force estimation methodology based on the disturbance observer theory. Monitoring methods using the cutting force and torque observer may enhance the productivity during drilling process in which one of the parameters that significantly affect the cutting process is the shear angle. The determination of the shear angle is very important as it can be used for identifying the machining conditions. In this study, an external sensor-less monitoring system of the shear angle during turning is developed, and its performance is evaluated. This paper deals with Proportional-Integral-Derivative (PID) controller used in a high performance drilling system for controlling the output obtained. The main objective is to obtain a stable, robust and controlled system by tuning, PID controller using minimization. The incurred value is compared with the traditional tuning techniques is improved better. Hence that drilling process results estimates the tuning in which PID controller using minimization technique gives less overshoot and better control performance with many advantages such as exibility, and reduced maintenance time and cost. In order to improve drilling efficiency while preserving tool life. , this study focuses on the design and implementation of an optimal fuzzycontrol system for drilling force. This 49-rule controller is networked and operates on a computer numerical control (CNC) machine tool. It is optimally tuned using a known maximum allowable delay to deal with uncertainties in the drilling process and delays in the network-based application.