A novel optimization algorithm based PID controller design for real-time optimization of cutting depth and surface roughness in finish hard turning processes

Abstract

This paper proposes a novel method to improve surface finish in turning processes by effectively controlling the cutting depth. A metaheuristic algorithm based PID control system, in combination with a piezoelectric vibration sensor for feedback, is introduced to regulate the position of the servo motor that controls the cutting tool. The PID controller is optimized using Q-learning based Sand Cat Optimization algorithm to achieve the best performance in terms of cutting depth accuracy and surface finish quality. The piezoelectric sensor provides realtime feedback information about the cutting process and allows for precise adjustments to the cutting depth. The results demonstrate the proposed system’s ability to handle variations in cutting conditions and tool’s wear and tear. Compared to highly optimized standard PID control, improved robustness and stability has been achieved in experimental results by proposed framework. Experimental results demonstrate improved robustness and stability compared to standard PID control. Several materials with high hardness of 20–65 HRC including Phenolic Bakelite, Copper, Thermoplastic, and Stainless Steel (AISI-420, AA6061-T6, and AISI-316) are tested. Minimum value of Vibration amplitude achieved is 0.598 μm for cutting depth of 0.25 mm. The sustained minimum amplitude of vibration and Ra value of the surface finish is found comparable to standard models with less than 10% error.