In this work an extended Model Reference Adaptive Control (MRAC) technique is used to control the cutting force of an end milling process. The technique incorporates Zero Phase Error Tracking Control (ZPETC) into the MRAC system. The extended MRAC controller remains stable even in the presence of marginally stable and nonminimum phase process zeros. A modified recursive least-squares estimation algorithm is used for on-line parameter identification. Simulation results are presente to compare the extended MRAC controller to the standard MRAC controller. A microprocessor system is used to implement adaptive force control of a single-input single-output milling process where the microprocessor monitors the system cutting forces and controls the desired feedrate. A constant cutting force is maintained in the presence of time-varying plant gains and a high random component of the output force. Experimental results are presented for standard MRAC and extended MRAC controllers for comparison.

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