A milling process adaptive control method, which prevents force overshoots during sudden part geometry changes, has been developed by providing online information to the controller from the part’s CAD representation. A first-order discrete model structure to represent the milling process for adaptive control was analytically developed and experimentally identified. Provided with geometric information obtained from the part’s CAD model, and utilizing the milling force model, the adaptive controller predicts the maximum cutting force expected in advance of dangerous immersion changes. The technique permits the controller to anticipate the changing workpiece in time to eliminate force overshoots which would otherwise break the tool, yet adaptive control at all times remains active to respond to other geometrical and material variations. Simulation and experimental results are presented to confirm the viability of the proposed method.

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