Application of Optimal Control Theory to Milling Process

A prototype for a supervising controller for machining applications is here proposed. The controller relies on the definition of an optimal control problem that aims at calculating the sequence of controls (feed rate and tool speed) that minimize a multi-objective target function. The target function allows to selectively prioritize terms related to the productivity, energy consumption, tool wear, and surface quality, by individually setting their relative weights (the case of all equal weights represents a balanced optimization.) The implementation of the proposed system on a real machine tool is briefly outlined, and the results of real machining tests are reported and compared to those obtained by typical machining on the same machine tool.