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Modified IMC Technique for Nonlinear Uncertain Milling CNC Machine Tool
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Article · June 2019

DOI: 10.1007/s13369-019-03984-7

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Arabian Journal for Science and Engineering
https://doi.org/10.1007/s13369-019-03984-7

RESEARCH ARTICLE - SYSTEMS ENGINEERING

Modified IMC Technique for Nonlinear Uncertain Milling CNC Machine

Tool System
Anil Kumar Yadav1 · Prerna Gaur2

Received: 10 August 2018 / Accepted: 19 June 2019

© King Fahd University of Petroleum & Minerals 2019

Abstract
The objective of this paper is to model a nonlinear computer numerical control machine tool (CNCMT) system for milling
process. A modified internal model control (M-IMC) technique is proposed for position control of machine table. The study
of milling process is mainly focused on the cutting mechanics and dynamics. The performance of CNCMT system is degraded
due to the presence of disturbance like cutting force and parametric uncertainty. Considering the limitation of conventional
internal model control (C-IMC) technique that is the poor performance under constant disturbance, an M-IMC technique is
designed for the rejection of disturbance and position control of uncertain nonlinear CNCMT system. The performances of
nonlinear uncertain CNCMT system using M-IMC technique is also compared with C-IMC and Ziegler–Nichols-tuned pro-
portional–integral–derivative control techniques. The proposed M-IMC technique is designed to attain the better disturbance
rejection capability, i.e., regulatory control with less control effort for the regulation of desired position of a machine table.

Keywords  Milling CNC machine tool system · Disturbance rejection · Modified IMC and nonlinear system

1 Introduction which occur during the machining process should be mini-

The CNCMT system is a highly integrated mechatronic sys-
tem, and it was developed to manufacture with high preci-
sion and accuracy. The CNCMT systems are used mainly
for drilling, cutting, milling, boring, finishing, welding and
aligning operations of manufacturing processes to ensure
the precision of machining products [1–3]. In CNCMT, the
information related to the shape of the workpiece, motion
and operation of machine table is stored in a computer pro-
gram and used in industries such as automotive, aerospace,
electrical and instrumentation. [4, 5]. In order to achieve
high precision and operational efficiency, the disturbances
* Anil Kumar Yadav
anilei007@gmail.com
Prerna Gaur
prernagaur@yahoo.com
1
Department of Electrical Engineering, NIT Hamirpur,
Hamirpur, HP 177005, India
2
Division of ICE, NSUT, Dwarka, New Delhi 110078, India
mized [6, 7].
In the milling process, certain nonlinearity like gear back-
lash [8] and unidentified forces can significantly degrade the
motion accuracy including the cutting, friction and inertial
forces, thermal and parameter variations [9–11]. The cut-
ting and friction forces that are a combination of Coulomb,
viscous and static are the dominant source of disturbance in
the position control of machine table [12]. The prediction
of cutting forces in milling process using feed drive current
measurements [13], disturbance observer [9, 14] and adaptive
neuro-fuzzy inference system [15] is discussed. The various
control techniques such as PID [5], observer-based control
[16], optimal linear quadratic regulator [17], H∞ control and
𝜇 synthesis [18], fuzzy logic and artificial neural network-
based controls [19–21] and model-based control [7, 22, 23]
related to CNC milling process are reported. In this work, the
analysis of disturbance rejection influenced by cutting force for
linear position (along x-axis) and angular speed (about z-axis)
controls of machine table and tool, respectively, is proposed.
The magnitude of cutting force is considered as constant and
randomly varying because the shape and size of workpiece are

13
Vol.:(0123456789)

even or uneven. The parametric uncertainty is due to lack of
precise knowledge of the actual CNCMT system parameters,
and is called as uncertain CNCMT system. To achieve the
desired position of machine table against the external distur-
bances and the parametric uncertainty, the M-IMC, i.e., IMC
with modified filter is proposed. However, more than 90% of
industrial controllers are PID type because it has simple struc-
ture, excellent performance, easy to design and inexpensive
[24–26]. Therefore, the performance of the nonlinear CNCMT
system using M-IMC technique is also compared with the PID
controller.
IMC strategy was introduced by Garcia and Morari [27],
and the design concept of IMC is widely recognized that can
achieve the robust performance for tracking and disturbance
rejection from the process output [28, 29]. The large and con-
stant steady-state error (Ess) is the limitation of C-IMC tech-
nique, i.e., IMC with conventional filter [30], which fails in
proper position alignment when machine table is subjected to
constant cutting force. In the design of IMC, low-pass filter
plays a significant role for servo and regulatory control opera-
tions [31]. The applications of IMC for various systems such
as speed control of heavy-duty vehicle [30, 31], load frequency
control in power system [32], speed control permanent magnet
synchronous motor [33] and DC–DC boost converter [34] are
discussed.
In this research, two types of control problems such as
servo and regulatory are discussed. In servo problem, the pur-
pose of the controller is to track the desired position and speed
of machine table and tool, respectively, whereas in regulatory
problem, the controller acts in such a way that the disturbance
whatsoever is swiftly minimized or is rejected completely.
The idea of this work is taken from the literature [4, 7, 16].
The key contributions of the paper are summarized as follows:
(1) the explicit modeling of the nonlinear CNCMT system
for motion of both x-axis and z-axis, (2) design of modified
IMC for x-axis and ZN-tuned PI for z-axis controls and (3)
a comparative performance analysis among ZN-tuned PID
control, C-IMC and M-IMC techniques is presented. For the
comparative analysis, the performance parameters such as
overshoot (OS), rise time (RT), settling time (ST), Ess, inte-
gral of the absolute error (IAE) and integral of the square of
the error (ISE) are studied to obtain the optimum all-round
performance of CNCMT system. The expected advantage of
the M-IMC technique over C-IMC technique is to improve the
regulatory performance by reducing the Ess under constant
disturbance. It also decreases the relative variations in IAE
and ISE of the nonlinear CNCMT system with and without
random disturbance and noise as compared to PID control and
C-IMC techniques. MATLAB/Simulink is used to simulate
the results.
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Arabian Journal for Science and Engineering
2 Problem Formulation and Modeling
of a Nonlinear CNCMT System
for the Milling Process
2.1 System Description and Problem Formulation
The components of the practical setup of CNCMT system for
milling process and mechatronic diagram of CNCMT system,
i.e., assembly of DC servomotor, gearbox, machine table and
lead screw shaft are shown in Fig. 1a, b, respectively. The cut-
ting force at the tip of machine tool is transmitted to the feed
drive and spindle, i.e., x-axis and z-axis motors, respectively,
as shown in Fig. 1a. Therefore, it is necessary to control or
to reject the disturbances on motors of both x-axis and z-axis
simultaneously. The input in the CNC machine tool is electri-
cal power to the power amplifier which gives the suitable volt-
age applied to the DC servo motor, and the output variables
might be the velocity and position of the machine table. Here,
two feedback loops of position and velocity are used. The
velocity feedback loop provides the additional damping ratio
which in turn improves the OS, and is employed where OS is
undesirable like in the milling process. The position control-
ler generates the control signal to the drive circuitry accord-
ing to error generated from desired and actual positions of
the machine table. The desired actual positions are generated
from computer programs and encoder output, respectively, as
shown in Fig. 1a. For the regulation of z-axis motion, a sensor
is mounted to the spindle [16] which sends the feedback signal
(i.e., force, torque or vibration) to the control unit, i.e., PI-type
angular motion controller as shown in Fig. 1a.
2.2 Mathematical Modeling and Open‑Loop
Behavior
2.2.1 Mathematical Modeling for x‑ Axis Linear Motion
In Fig. 1b, a DC servo motor is employed to rotate the lead
screw shaft of CNCMT system, which controls the position
of machine table. Applying the Kirchhoff’s voltage law in the
electrical loop of the DC servo motor as shown in Fig. 1b, the
relation is as follows:
dia
Ea − Eb = Ra ia + La (1)
dt
where Ea is the applied voltage, ia is the armature current,
Ra and La are the armature resistance and the inductance of
the motor, respectively. Eb is the(back electromotive force
)
(EMF) and is defined as Eb = Kb d𝜃m ∕dt  , where Kb is the
back EMF constant. The mechanical dynamics of motor
shaft and lead screw shaft, i.e., output shaft is as follows:
d2 𝜃m d𝜃
Jm + Bm m + TL = Tm (2)
dt2 dt
Arabian Journal for Science and Engineering
Fig. 1  a Components of the practical setup of CNCMT system for milling process and b mechatronic diagram of CNCMT systems
d2 𝜃 d𝜃
J0 20 + B0 0 + TD = Tg (3)
dt dt
where Jm and Jo are the inertia of the motor and lead screw
shafts, respectively, Bm and Bo are damping coefficients of
the motor and lead screw shafts, respectively. 𝜃m and 𝜃o are
angular positions of motor and lead screw shafts, respec-
tively, TL and Tg are the input and output torques of the
gear box, respectively. The motor torque Tm is defined as
Tm = Kt ia , where Kt is motor torque constant. TD is the dis-
turbance torque. In CNCMT system, the disturbance torque
TD is generated from some external forces such as cutting
and frictional forces during machine table(movement.
) The
disturbance torque TD is defined as TD = GD Fc + Ff , where
Fc and Ff are the cutting and frictional forces, respectively.
( )
GD is the transmission gain that is the function of f p, 𝜂e , N  ,
where p, 𝜂e andN are pitch of lead screw shaft, efficiency of
the CNCMT system and the gear ratio, respectively [1]. The
direct proportionality in disturbance forces and torques, i.e.,
GD = 1 is considered in this study. The Coulomb, viscous
and static frictional forces in the motion of machine table
are described as follows [13, 14]:
{ }
( ) −|| v(t) ||𝛿
Ff (v(t)) = Fco + Fs − Fco ⋅ e | V s | + Fv ⋅ |v| ⋅ sign(v(t))
(4)
where Fco , Fs and Fv are Coulomb, static and viscous fric-
tion coefficients, respectively. Vs and 𝛿 are the Stribeck
velocity and the Stribeck shape factor, respectively, v(t) is
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 Arabian Journal for Science and Engineering

linear velocity of machine table on lead screw shaft, i.e., (7), (9) and (10), the mechatronic coupling of DC servomo-
v(t) = ẋ 0 (t) , and sign(v) is the signum function of v and tor, gear backlash, lead screw shaft and machine table of
defined as sign(v) = 1 , if v > 0 , sign(v) = 0, if v = 0 and CNCMT system is obtained, which is represented by (11)
sign(v) = −1 , if v < 0. and (12).
The hard nonlinearity like gear backlash is discussed in
Kb N dx0 (t) di (t)
[8], which is generally expressed as follows: Ea − ⋅ = Ra ia + La a (11)
p dt dt
⎧ N �T − 𝜌�, Ṫ > 0 and T (t) = N �T (t) − 𝜌� ⎫
⎪ � L � L g � L �⎪ ( ) J B
Tg (t) = ⎨ N TL + 𝜌 , Ṫ L < 0 and Tg (t) = N TL (t) + 𝜌 ⎬ N ⋅ Kt ⋅ ia (t) − GD Fc (t) + Ff (t) − ⋅ ẍ 0 (t) − ⋅ ẋ 0 (t) = p ⋅ m ⋅ ẍ 0 (t)
p p
⎪ No change, otherwise ⎪
⎩ ⎭ (12)
(5) 2.2.2 Mathematical Modeling for z‑Axis Angular Motion
where 𝜌 is the backlash distance and N is the gear ratio. It
is noted that in the simulation, original backlash model is The dynamics of servomotor for z-axis angular motion is
used, whereas in controller design, the backlash model (5) described as follows [4, 16]:
is replaced by (6): 𝜏m (t) = kt i = Je 𝜔(t)
̇ + Be 𝜔(t) + 𝜏c (13)
Tg (t) = NTL (t) + d(TL (t)) (6) where Je and Be are the equivalent inertia and equivalent
where d(⋅) is a nonlinear function on TL (t) and TL (t) , and
̇ damping coefficient, respectively,𝜔(t) is the angular speed
bounded such as ||d(TL (t))|| ≤ 𝛼 where 𝛼 is the corresponding of z-axis motor. 𝜏m is the motor torque, kt is motor torque
upper bound [8]. Generally, the term d(TL (t)) is considered constant, i is current of z-axis motor and 𝜏c is the torque due
with disturbance torque with the uncertain bound. Therefore, to cutting force.
Tg (t) = NTL (t) and 𝜃m = N𝜃0 are considered. Put 𝜃m = N𝜃0 The block diagram of a nonlinear CNCMT system for
( ) ( ) control application of linear position along x-axis and angu-
in Eb = Kb d𝜃m ∕dt  , and yield Eb = Kb ⋅ N ⋅ d𝜃0 ∕dt  . Put
lar speed about z-axis is given by Fig. 2, which is designed
this value of Eb in (1), and (7) is obtained.
using Fig. 1, and (11)–(13). In Fig. 2, ­H2 is the gain of tacho-
d𝜃0 di generator, Ka is the gain of power amplifier and u is the
Ea − Kb N = Ra ia + La a (7) controlled input to the motor for motion of x-axis, whereas
dt dt
kai is the gain of current amplifier and u′ is the controlled
Put Tg (t) = NTL (t) in (3), after that put the value of TL
input to the motor for motion of the z-axis. In Fig. 2, a delay
from (2) to (3)
term e−Td s is incorporated which signifies the delays among
( ) rotational motions of motor and lead screw shafts, and linear
d2 𝜃0 d𝜃0 d2 𝜃m d𝜃m
J0 2 + B0 + TD = N Tm − Jm 2 − Bm motion of machine table, and it also improves the modeling
dt dt dt dt accuracy toward practical applications [32].
(8)
Put 𝜃̈m = N 𝜃̈0 in (8) and rearranging them
2.2.3 Open‑Loop Behavior of System for x‑Axis and z‑Axis
2 2 Motions
d 𝜃0 d𝜃 d𝜃
NTm − TD = N 2 Jm 2
+ J0 20 + N 2 Bm 0
dt dt dt From Fig. 2, it is clearly seen that the nonlinear CNCMT
d𝜃0 d 2 𝜃0 d𝜃 system has three inputs, i.e., u, u′ and Fc , and two outputs,
+ B0 ⇒ NTm − TD = J 2 + B 0 (9)
dt dt dt i.e., linear position x0 and angular speed 𝜔 ; therefore, it may
be called as multi-input multi-output (MIMO) system. The
where J and B are the equivalent inertia and damping coef- nominal values and parametric uncertainty of CNCMT sys-
ficient, respectively, and described as J = N 2 Jm + J0 and tem parameters are given in Table 1. In this table, ­H1 is the
B = N 2 Bm + B0. gain of encoder and Td is the delay time. The open-loop step
In order to establish the relation between the rotational response of actual nonlinear and linearized CNCMT systems
motion of lead screw shaft and linear position of machine with nominal values as given in Table 1 under the influence
table assuming that the work-in is equal to work-out that is of constant Fc as disturbance of 500 N is shown in Fig. 3a, b.
represented as follows: To show the effect of disturbance on open-loop per-
NTm (t) − TD (t) − J 𝜃̈0 (t) − B𝜃̇ 0 (t) = p ⋅ m ⋅ ẍ 0 (t) (10) formance of nonlinear and linearized CNCMT systems,
Fc is applied at 20 s. From Fig. 3a, b, the open-loop step
where m is combined mass of machine table and mass of
responses are unstable because it does not give bounded
workpiece, x0 is the linear position of machine table on lead
output for bounded input. In order to achieve the desired
screw shaft, the pitch p is defined as p = x0 (t)∕𝜃0 (t) . From

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Arabian Journal for Science and Engineering

Fig. 2  Block diagram of a nonlinear CNCMT system for control application of x- and z-axis motion

Table 1  Nominal values and parametric uncertainty of CNCMT sys- system. In this paper, conventional low-pass filter like
tem 1∕(𝜇s + 1)n is replaced by a filter named
( ) as, modified filter
Symbols with nominal values Parametric uncertainty having structure as 𝜗s3 + 𝜆s2 + 𝜑s + 1 ∕(𝜇s + 1)n , where 𝜗 ,
𝜇 , 𝜆 , 𝜑 and n are filter parameters. In conventional filter, ′ 𝜇′
Ra 0.613 Ω ∈ [0.4, 0.8] maintains the position tracking and disturbance rejection of
La 2.158 mH ∈ [1, 3] the system. The ′ 𝜇′ effectively tackle the speed of response
Kb 0.34 Vs/rad ∈ [0.2, 0.5] because it is a time constant, whereas in modified filter the
Kt 1.01 Nm/A ∈ [0.5, 1.5] additional parameters 𝜗 , 𝜆 and 𝜑 are suitably designed to
kt 1.343 Nm/A ∈ [0.7, 1.9] improve the regulatory performance of the system. The
m 105 kg ∈ [75, 140] parameters 𝜗 , 𝜆 and 𝜑 are contributing in the zeros of the
[ ]
Jm 3.7 ∗ 10−3 ­Kgm2 ∈ 2 ∗ 10−5 , 5 ∗ 10−4 system; therefore, the modified filter incorporated the fea-
J0 0.00154 ­Kgm2 ∈ [0.0005, 0.0025] tures of adding zeros in the control system like disturbance
Je 0.0316 ­Kgm2 ∈ [0.02, 0.05] rejection. Therefore, IMC with modified filter is proposed
[ ]
Bm 1.34 ∗ 10−4 Nms/rad ∈ 0.5 ∗ 10−5 , 3 ∗ 10−3 in this paper, which improves the regulatory control, i.e.,
B0 0.002 Nms/rad ∈ [0.001, 0.003] disturbance rejection. The modified filter is considered as
Be 0.009 Nms/rad ∈ [0.008, 0.01] third order because the order of modeled nonlinear CNCMT
Ka 2 ∈ [1, 3] system is three. The structure, i.e., order of modified filter
kai 6.4841 ∈ [5, 8] can be changed according to order of system or internal
Fco 10 N ∈ [5, 15] model (IM) that is derived from original system.
Fs 20 N ∈ [15, 25] For the design of controller, a linearized model of
Fv 15 N ∈ [10, 20] CNCMT system is required. Taking the Laplace transforms
Vs 0.1 m/s ∈ [0.08, 0.12] of (11) and (12), and for simplicity neglecting the small
𝛿 2 ∈ [1.5, 2.5] value of La [8], yields (14a) and (14b):
Td 0.2 s ∈ [0.1, 0.3] ( )/
Kb ⋅N
𝜌 0.75 – Ia (s) = Ea (s) − s ⋅ X 0 (s) (14a)
p
a R
p 5 mm –
N 6:1 (N2 ∕N1 ) –
H1, ­H2 1, 1.2 – ( ) J
N ⋅ Kt ⋅ Ia (s) − GD Fc (s) + Ff (s) − ⋅ s2 ⋅ X0 (s)
p
B
speed and position of machine tool and machine table − ⋅ s ⋅ X0 (s) = p ⋅ m ⋅ s2 ⋅ X0 (s) (14b)
p
respectively; classical PI and PID controllers, and C-IMC
and MIMC techniques are designed via linearized system Put the value of Ia (s) from (14a) into (14b), yields
and simulated with original nonlinear system. Here, it is ( ) (15) by
assuming the disturbance torque TD = GD Fc + Ff = 0 , i.e.,
noted that the nonlinearities due to frictional model and disturbances due to cutting and frictional forces are zero.
gear backlash are omitted while considering the linearized

13
 Arabian Journal for Science and Engineering

Fig. 3  Open-loop step response

of CNCMT systems a for x-axis
motion b for z-axis motion

The locations of the poles depend on the CNCMT system

⎛ Ea (s) − Kb ⋅N s ⋅ X0 (s) ⎞ parameters that have parametric uncertainty. Therefore, it is
N ⋅ Kt ⎜
p
⎟ − J ⋅ s2 ⋅ X (s) required to design a robust controller which effectively tack-
⎜ Ra ⎟ p 0
⎝ ⎠ les the uncertainty and improves the system performance.
B
− ⋅ s ⋅ X0 (s) = p ⋅ m ⋅ s2 ⋅ X0 (s) (15)
p
3 Control Strategy for Milling CNCMT
The transfer function of coupled DC motor, gearbox, lead System
screw shaft and machine table is obtained after rearranging
(15), which is as follows: 3.1 PI and PID Control Method
[ 2 ( )]
(p mRa + Ra J)s + N 2 Kt Kb + BRa sX0 (s) = pNKt Ea (s) A PID controller can be written as ‘parallel’ or ‘ideal’ form
( ( 2 )) that is given by (18) or (19), respectively [24].
s ⋅ X0 (s) 2
N Kt Kb + BRa

∫
= pNKt ∕(p mRa + Ra J)∕ s +
Ea (s) (p2 mRa + Ra J) u(t) = KP e(t) + KI e(t)dt + KD e(t)
̇ (18)
(16)
From Fig. 2 and (16), the open-loop transfer function of [ ]

TI ∫
1
CNCMT system from delayed output X0 (s) to controlled input u(t) = KP e(t) + e(t)dt + TD e(t)
̇ (19)
U(s) is as follows:
where KP , KI and KD are proportional, integral and derivative
Ka ⋅ N ⋅ Kt ⋅ p/ 2 gains, respectively, TI and TD are the integral and derivative
X0 (s) (p mRa + Ra J) −T s
G(s) = = ( ) ⋅e d (17) time constants, respectively, and u(t) and e(t) are output and
U(s) N 2 K K +BR +K NK H
s s+ input to the controller, respectively. The parameters of pro-
t b a a t 2
(p2 mR +R J)
a a
portional (P), proportional–integral (PI) and PID controllers
The linearized CNCMT system (17) is a second-order are computed using ZN tuning method [25] using relations
plus time delay system which has one pole at the origin;
hence, the open-loop CNCMT system is marginally stable.

13
Arabian Journal for Science and Engineering

as follows: for P controller: KP = 0.5Ku , for PI controller: 3.3 Modified IMC (M‑IMC) Technique
KP = 0.4Ku and TI = Tu ∕1.2, and for PID controller:
Since IMC with F(s) has limitation for the rejection of dis-
KP = 0.6Ku , TI = Tu ∕2, TD = Tu ∕8, KI = KP ∕Ti and KD = KP ⋅ TD .
turbance; therefore, F(s) of (22) is replaced by modified filter
(20)
F � (s) which is as follows:
where Ku and Tu are the ultimate gain and period of the sys-
tem, respectively. 𝜗s3 + 𝜆s2 + 𝜑s + 1
F � (s) = (24)
(𝜇s + 1)n
3.2 Conventional IMC (C‑IMC) Technique
where 𝜗 , 𝜆 and 𝜑 should satisfy the condition as given in
The generalized architecture of conventional IMC is presented (25) for poles p1 , p2 and p3 of IM, and n = 5 or 6 , depend-
in Fig. 4. It has IM Gm (s) , controller C(s) , which has inverse ing upon the requirement to make controller proper. The
IM, i.e., G−1 proposed filter can be modified according to the order and
m (s) and low-pass filter F(s) , the uncertain CNCMT
system G(s) and the cutting force as disturbance d , ẽ is the type of the IM.
matching error between CNCMT system and IM, and Xd (s)
Lim (1 − T(s)) = 0, i = 1, 2 and 3. (25)
and X0 (s) are desired and actual positions of the machine table, s→pi
respectively.
The complete rejection of disturbances, perfect position where T(s) = C(s) ⋅ Gm (s) (26)
tracking and the minimizing the effect of noise is achieved if From (22) and (24)
Gm (s) = G(s) , and Gm (s) has breakup as follows:
1 𝜗s3 + 𝜆s2 + 𝜑s + 1
Gm (s) = G−m (s).G+m (s) (21) C(s) = ⋅ (27)
G−m (s) (𝜇s + 1)n
where G−m (s) is minimum phase term and G+m (s) is non-mini-
mum phase term. G+m (s) contains zeros at right-hand part and Put Gm (s) = G−m (s) ⋅ G+m (s) from (21) and C(s) from (27)
the time delay; its steady-state gain must be unity. Thus, the in (26), we get
steady-state gain of Gm (s) will remain in G−m (s) that is used
to design of C-IMC C(s) which is as follows: 𝜗s3 + 𝜆s2 + 𝜑s + 1
T(s) = G+m (s) ⋅ (28)
(𝜇s + 1)n
1
C(s) = − ⋅ F(s)
Gm (s) (22) For the calculation of filter parameters which are
𝜗, 𝜆and 𝜑 , G+m (s) = e−Td ⋅s is considered as shown in (17).
where F(s) is a low-pass filter. The conventional low-pass From (28), T(s) is as follows:
filter is described as:
( )
e−Td ⋅s 𝜗s3 + 𝜆s2 + 𝜑s + 1
(23)
n
F(s) = 1∕(𝜇s + 1) T(s) = (29)
where 𝜇 is the tuning filter parameter, which maintains (𝜇s + 1)n
position tracking, disturbance rejection and robustness of
From (29), put the value of T(s) in (25) and simplifying
the system, and n is an integer and selected on the basis of
it, we get (30):
C(s) when it becomes proper or semi-proper for physical
[ ( )]
realization. (𝜇s + 1)n − e−Td ⋅s 𝜗s3 + 𝜆s2 + 𝜑s + 1
Lim =0
s→pi (𝜇s + 1)n

(𝜇s + 1)n
⇒ 𝜗s3 + 𝜆s2 + 𝜑s + 1 = (30)
e−Td ⋅s
For Lim  , putting s = p1 , p2 and p3 in (30), (31)–(33)
s→p1, p2, p3
are obtained as a result which are as follows:
( )n
𝜇p1 + 1
𝜗p31 + 𝜆p21 + 𝜑p1 + 1 = (31)
e−Td ⋅p1

( )n
𝜇p2 + 1
𝜗p32 + 𝜆p22 + 𝜑p2 + 1 = (32)
Fig. 4  Block diagram of the conventional IMC for CNCMT system e−Td ⋅p2

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 Arabian Journal for Science and Engineering

( )n unaffected by gain and time constant of the system but

𝜇p3 + 1 only effected by delayed term e−Td s and 𝜇 as given in the
𝜗p33 + 𝜆p23 + 𝜑p3 + 1 = (33) first term of (37). The 𝜇 can further be reduced enough to
e−Td ⋅p3
improve the disturbance rejection performance [31, 33].
Equations  (31–33) are derived for third-order system/ Now,( consider ing ) t he case of M-IMC, t he
IM. For a delayed integrating system, i.e., pole at the origin, F � (s) = 𝜆s2 + 𝜑s + 1 ∕(𝜇s + 1)n for the system (17) is
Eqs. (31–33) are not applicable because the filter parameters similar to G(s) = K ⋅ e−Td s ∕s(Ts + 1) . The original line-
disappear at origin s = 0 , i.e., p = 0 . Therefore, a stable or an arized system is approximated as
unstable pole near zero may be considered for delayed integrat- G(s) = 𝜀 ⋅ K ⋅ e−Td s ∕(𝜀s + 1)(Ts + 1) because it has one pole
ing system [29], the approximation is as follows: 2 +𝜑s+1
at origin. Hence, put C(s) = G−1(s) ⋅ 𝜆s(𝜇s+1)4 in (36):
m
G(s) = Ke−Td s ∕s(Ts + 1) ≅ 𝜀Ke−Td s ∕(𝜀s + 1)(Ts + 1) (34) ( 2 )
where K and 1∕T are the gain and pole of the system, respec- 𝜆s + 𝜑s + 1 e−Td s
X0 (s) = Xd (s)
tively. 𝜀 is a real positive number, and in this work, it is (𝜇s + 1)4
considered as 1000. The application of proposed modified [ ( ) ]
(𝜇s + 1)4 − 𝜆s2 + 𝜑s + 1 e−Td s
IMC technique to nonlinear CNCMT system in the form of + G(s) D(s)
block diagram is given in Fig. 5. (𝜇s + 1)4
(38)
3.4 Comparative Analysis of C‑IMC and M‑IMC
For the disturbance rejection analysis, the second term
Techniques for Disturbance Rejection
of (37) and (38) is compared. It can be seen that in (38),
there are additional zeros; therefore, it may enhance the
In order to show the advantage of F � (s) over F(s) of IMC,
disturbance rejection capability and is shown in Fig. 6a.
consider the standard form of linearized CNCMT system (17)
The disturbance rejection capability for z-axis motion
which is as follows: G(s) = Ke−Td s ∕s(Ts + 1) . From Fig. 4
using simple proportional controller, i.e., unity gain and a
[ ] ZN-tuned PI controller is presented in Fig. 6b. The loca-
G(s)C(s) G(s) 1 − C(s)Gm (s)
X0 (s) = [ ] Xd (s) + [ ] D(s) tions of zeros are dependent on filter parameters 𝜇 , 𝜆 and
1 + C(s) G(s) − Gm (s) 1 + C(s) G(s) − Gm (s)
(35) 𝜑 that can be tuned properly to improve the regulatory
performances of milling CNCMT system. From Fig. 6a,
For the perfect model, i.e., Gm (s) = G(s) , (35) becomes:
[ ] the Ess in position of machine table under unit step distur-
X0 (s) = G(s)C(s)Xd (s) + G(s) 1 − C(s)Gm (s) D(s) (36) bance, i.e., constant cutting force using M-IMC is nearly
Considering the case of C-IMC, put C(s) = 1
⋅ 1
in zero, whereas it is 5.4 mm using C-IMC. Therefore, the
G−m (s) (𝜇s+1)2 proposed M-IMC technique enhances the disturbance
(36), yields rejection capability as compared to C-IMC technique.
[ ]
e−Td s (𝜇s + 1)2 − e−Td s
X0 (s) = Xd (s) + G(s) D(s)
(𝜇s + 1)2 (𝜇s + 1)2 4 Simulation Results and Discussion
(37)
From (37), it is observed that the complete system In this section, the simulated results, performance evalua-
transfer function G(s) appeared in the disturbance term tion and practical aspects of proposed controllers for milling
D(s) which affects the cutting force disturbance rejection CNCMT system are presented.
performance, and the closed-loop position response is

Fig. 5  Block diagram of modi-

fied IMC for nonlinear CNCMT
system

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x 10
-3
According to a proper balance in all the performance
6
specifications as given in Table 2, 𝜇 = 0.5 is selected for
5 C-IMC and M-IMC of nonlinear CNCMT system for further
study in this paper.
4
The C-IMC CC - IMC (s) with 𝜇 = 0.5 and n = 2 , and from
Position (m)

3 (17), (22) and (23), it is as follows: CC - IMC (s) =

2 
. For the design of M-IMC, the filter
s(0.0055s+1) 1
Ess
0.0045
∗ (0.5s+1)
2
Eq. (24) and (31)–(33) are modified according to number of
1 poles of the CNCMT system (17); it is as follows:
n
2 +𝜑s+1 (𝜇p1 +1)
F � (s) = 𝜆s(𝜇s+1)n , 𝜆p1 + 𝜑p1 + 1 = and 𝜆p22 + 𝜑p2
2
0 −T
e d 1⋅p
n
C-IMC M-IMC (𝜇p +1)
-1 +1 = e−T2d ⋅p2 . From (17) and (34), nominal numerical values
0 2 4 6 8 10
t (seconds) as given in Table  1: put p1 = −0.001, p2 = −183.1 ,
Td = 0.2, n = 4 and 𝜇 = 0.5 in above equations, 𝜆 = 0.012
(a)
and 𝜑 = 2.1981 are obtained. Similarly determine the values
of 𝜆 and 𝜑 for other values of 𝜇 . Therefore, the M-IMC
CM - IMC (s) for 𝜇 = 0.5 is as follows: CM - IMC (s) =
0.012s2 +2.198s+1 5.5s2 +1000.01s+1
(0.5s+1)4
∗ 4.5
 . The response for position of
nonlinear CNCMT system with different values of 𝜇 such as
0.1, 0.5 and 1.0 of M-IMC is shown in Fig. 8. In same figure,
𝜇 = 0.5(L) shows the response of linearized system for
𝜇 = 0.5 of M-IMC that implies the response of linear and
nonlinear CNCMT system is almost similar for same values
of 𝜇 . The M-IMC with 𝜇 = 0.1 gives high undesirable servo
OS nearly 75%,𝜇 = 1.0 gives large RT, ST and lesser distur-
bance rejection capability, and 𝜇 = 0.5 gives acceptable
servo OS, RT and ST, and regulatory performances for both
(b) linearized and nonlinear CNCMT system as shown in Fig. 8.
Hence, M-IMC with 𝜇 = 0.5 is selected for nonlinear
Fig. 6  Rejection of step disturbance a using C-IMC and M-IMC tech-
CNCMT system for further analysis.
niques for x-axis position b using ZN-PI controller for z-axis speed

Table 2  Performance index of CNCMT system with C-IMC

4.1 Response for Selection of Filter Parameter 
C-IMC OS (%) RT (s) ST (s) Ess (%)
under distur-
The unit step position response of CNCMT system with
bance
𝜇 = 0.5, 1and1.5 of C-IMC is shown in Fig. 7. Their per-
formances in terms of OS, RT, ST and Ess under constant 𝜇 = 0.5 2.15 3.10 2.8
disturbance, i.e., Fc = 100N that is applied at 20 s are given 𝜇 = 1.0 ≅0 4.4 6.03 5.1
in Table 2 for the selection of suitable value of 𝜇. 𝜇 = 1.5 6.1 8.95 7.2

Fig. 7  Response of CNCMT
system with 𝜇 = 0.5, 1and1.5 of
C-IMC techniques

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4.2 Comparative Tracking Performance Under Table 3  Parameters of ZN-tuned P, PI, PID and manual PID control-
Constant Disturbance lers
x-/z-axis motion Controller KP KI KD
For the design of P, PI and PID controllers, Ku and Tu are
For x-axis ZN-P 1078.75 – –
evaluated using Routh table (see Appendix 1). The param-
ZN-PI 863 1569.10 –
eters of P, PI and PID controllers are calculated using (20)
ZN-PID 1294.20 3957.80 106.80
and given in Table 3. The response of nonlinear CNCMT
Manual PID 800 1700 90
system with ZN-tuned PID controller is compared with ZN-
For z-axis ZN-PI 1.2 210 –
tuned P, PI and manual PID controllers as shown in Fig. 9a.
The ZN-tuned PID controller gives undesirable OS nearly
200%. Therefore, the PID controller’s parameters are manu-
ally adjusted based on the knowledge and called as manual controller and C-IMC technique. The large Ess in position is
PID controller. From Fig. 9a, the manual PID controller undesirable for position control applications because under
reduces the OS from 200 to 50% and gives a better regula- this condition desired position can never be achieved and
tory performance as compared to ZN-tuned P, PI and PID cannot be tolerated for CNC milling operations like cutting,
controllers. Hence, the manual PID controller is selected for boring, drilling and finishing.
further comparative analysis.
The desired position regulation and disturbance rejection 4.3 Robustness Analysis Under Parametric
of system using PID controller, C-IMC and M-IMC tech- Uncertainty
niques for 𝜇 = 0.5 for comparative performance analysis are
presented in Fig. 9b. In same figure, the desired position is To check the suitability of proposed controller for the
assumed to be unity and a constant cutting force of 500 N uncertain nonlinear CNCMT system, the parametric uncer-
for 20–40 s is applied. The speed response about z-axis of tainty as given in Table 1 is taken into consideration, and
CNCMT system using ZN-PI controller is presented in the response with PID control, C-IMC and M-IMC tech-
Fig. 9c. niques is presented in Fig. 10a–c, respectively. The position
From Fig. 9b, the maximum deviation and constant Ess in response in Fig. 10a–c is plotted after taking nominal, lower
the position of machine table under constant disturbance are (L) and upper (U) limit values of CNCMT system as given
nearly 11.4% using C-IMC, whereas the maximum devia- in Table 1. The performance index of the uncertain nonlin-
tion in position about 9.8% and it is regulated within 4.7 s ear CNCMT system with PID control, C-IMC and M-IMC
using M-IMC. Hence, the improvement in constant distur- techniques is given in Table 4.
bance rejection capability using M-IMC is observed as com- From Table 4 and Fig. 10a–c, it is clearly seen that the
pared to C-IMC technique. The nonlinear CNCMT system effect of parametric uncertainty, i.e., L and U limit values
under constant disturbance with C-IMC does not approach of the nonlinear CNCMT system on servo performance in
the desired position of 1 m; it is saturated at position of terms of OS and ST is very less, i.e., narrow bands of OS
0.886 m. The milling CNCMT system with PID controller and ST. The narrower bands of performance specifications
gives higher servo OS and better regulatory, i.e., disturbance give similar performance under parametric variations, i.e.,
rejection performance as compared to C-IMC and M-IMC the robustness of the nonlinear CNCMT system toward
as shown in enlarged view of Fig. 9b, whereas C-IMC gives the parametric uncertainty is achieved with the proposed
better servo (set position tracking without disturbance) controller.
performance as compared to PID and M-IMC techniques. From Fig. 10a, the position response with PID control-
According to proper balance in servo and regulatory control, ler gives high OS, i.e., nearly 151% while considering the
M-IMC is better for nonlinear CNCMT as compared to PID upper limit value and is undesirable. The Ess in the position

Fig. 8  Response of nonlin-
ear CNCMT system with
𝜇 = 0.1, 0.5and1 of M-IMC

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Fig. 9  a Response of nonlinear

CNCMT system with ZN-tuned
P, PI, PID and manual PID con-
trollers. b Response of nonlin-
ear CNCMT system using PID
controller, C-IMC and M-IMC
for 𝜇 = 0.5 . c Speed response
of CNCMT system using ZN-PI
controller about z-axis

of machine table is neither conversing nor constant after
disturbance using C-IMC with the lower limit values as seen
in Fig. 10b. From the enlarged view of Fig. 10c, the effect of
regulatory performance with change in parameters to upper
and lower limits of CNCMT system on position of machine
table, the maximum variation in position is seen as low
when the upper limit values of parameters are selected; it is
high when the lower limit of parameters is selected, and it is
nominal with nominal values of system parameters. Hence,
the proposed control technique is well suited for position
tracking and disturbance rejection of uncertain CNCMT sys-
tem for less low limit and high upper limit values of system
parameters.
4.4 Comparative Performance Analysis Under
Non‑deterministic Disturbance and Noise
Figure 11a, b shows the position response of the nonlinear
machine table without and with non-deterministic distur-
bance and sensor noise, respectively. The corresponding
controller output u(t) , i.e., control effort for position response
of nonlinear CNCMT system is shown in Fig. 12a, b. The
non-deterministic disturbance due to cutting force is shown
in Fig. 13 that signifies uneven shape and size of work-
piece. The noise signal that is also known as sensor noise
is usually generated during measurement of output position
from encoder as shown in Fig. 14. The performance index
of controlled nonlinear CNCMT system with and without
non-deterministic disturbances and noise in terms of IAE
and ISE is presented in Table 5.

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Fig. 10  Response of uncertain
nonlinear CNCMT system with
a PID control b C-IMC and c
M-IMC techniques

Table 4  Performance indexes of controllers for CNCMT with nomi- The values of IAE and ISE are determined using
nal, L and U limit system parameters IAE = ∫0 |e(t)|dt and ISE = ∫0 e2 (t)dt after taking T = 60
T T

s and e = Xd (t) − X0 (t) . The energy content Eu of controller

output u(t) is calculated using Eu = ∫0 |u(t)|2 dt  , where |⋅|
Controller Parameters (%) Max. position
T
deviation after distur-
Before disturbance (servo) bance represents the two-norm. The numerical values of energy
OS (%) ST (s) content for PID control, C-IMC and M-IMC techniques are
PID given in Table 5. Figure 15 shows the effect of gear back-
 Nominal 50.5 2.85 0.31 lash nonlinearity on position of CNCMT system with the
 U–L 35.6–151 2.4–6.6 0.25–0.4 proposed M-IMC technique. The nonlinear CNCMT system
C-IMC with backlash nonlinearity has nearly twice the Ess as com-
 Nominal ≅0 2.1 2.6 pared to that of without backlash nonlinearity using pro-
 U–L ≅0 1.9–2.5 1.5–5.3 posed M-IMC as shown in enlarged view of Fig. 15.
M-IMC The aim of designing M-IMC technique as robust control-
 Nominal 42.5 5.9 2.55 ler is to serve under uncertain, servo and regulatory condi-
 U–L 30.4–61.8 5.5–6.8 1.5–3.5 tions. From the facts of Table 5, the C-IMC technique gives
least values of IAE, ISE and energy content of control effort
for a nonlinear CNCMT system with and without non-deter-
ministic disturbances and noise as compared to PID control

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Fig. 11  Response of nonlin-
1.5
ear CNCMT system with all

Position (m)
designed controllers a without 1
and b with non-deterministic
disturbance and noise 0.5
desired PID C-IMC M-IMC
0
0 10 20 30 40 50 60
t (s)
(a)

1.5

Position (m) 1

0.5
desired PID C-IMC M-IMC
0
0 10 20 30 40 50 60
t (s)
(b)

Fig. 12  Output of controllers x 10
4

when nonlinear CNCMT system

Controller Output u(t)

5 PID C-IMC M-IMC

subjected to a without and b
with non-deterministic distur-
bance and noise 0 200
1000
100
-5 500
0 0

0 1 2 3 4 5 45 46 47 48 49 50
-10
0 10 20 30 40 50 60
t (s)
(a)

(b)

Fig. 13  Disturbance due to cut- 60

(Cutting Force)

ting force
Disturbance

40

20

0
0 10 20 30 40 50 60
t (s)

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 Arabian Journal for Science and Engineering

Fig. 14  Noise signal
2

Noise
0
-2 2
0
-4 -2
-6 20 20.2 20.4 20.6 20.8 21
0 10 20 30 40 50 60
t (s)

Table 5  Performance index of the nonlinear CNCMT system with designed controllers

Parameters without disturbance and noise with disturbance and noise Percentage (%) relative variation
Controller IAE ISE Energy content IAE ISE Energy content IAE ISE Energy content

PID 2.001 0.8226 5.016 × 106 48.35 61.57 2.435 × 1011 2316.3 7384.8 4.8535 × 105
C-IMC 3.90 1.692 5.061 × 104 4.82 1.734 5.82 × 104 23.12 2.48 13.89
M-IMC 4.759 1.99 1.562 × 105 5.695 2.008 1.66 × 105 19.67 0.9045 6.27

The bold values show the best results

Fig. 15  Position response of
the nonlinear CNCMT system
with and without backlash using
M-IMC technique

and M-IMC techniques, whereas the M-IMC technique
improves the varying disturbances and sensor noise rejec-
tion capability in terms of percentage relative variations in
IAE and ISE of the nonlinear CNCMT system, i.e., variation
between the conditions without and with disturbance and
noise as compared to PID control and C-IMC techniques.
Hence, it can be concluded that the nonlinear CNCMT sys-
tem with M-IMC gives better non-deterministic disturbance
and noise rejection capability in terms of percentage relative
variations in IAE, ISE and energy content of control effort as
compared to PID control and C-IMC techniques. The least
value of energy content of the control effort signifies that the
minimum physical energy is required to drive the system.
5 Conclusion
In this paper, a milling CNCMT system (for both x-axis and
z-axis) along with PI and PID controls, C-IMC and M-IMC
techniques is designed, and implemented successfully for
constant and varying disturbance rejection due to cutting
force. The nonlinear CNCMT system with PID controller
gives higher OS in servo control, and better regulatory
performance under constant disturbance rejection as com-
pared to C-IMC and M-IMC techniques, whereas C-IMC
gives better performance under varying disturbance as
compared to PID control and M-IMC techniques. A com-
parative performance analysis of PID control, C-IMC and
M-IMC techniques vividly show that according to proper
balance in uncertainty, servo and regulatory (under both
constant and varying disturbances) performances, M-IMC
is better in all performances except servo OS as compared
to PID controller and C-IMC technique. The M-IMC has
eliminated the disturbance within desired value, which is
highly desirable for position control applications where the
disturbance and noise signal lead to more energy loss and
degrade the position accuracy.
The expected advantage of the M-IMC over C-IMC
technique is also achieved. The proposed control technique
may also be applicable for reconfigurable milling CNCMT
systems that enhances the manufacturing efficiency and
also for disturbance rejection of other systems. For better
performance, PID controller’s parameters can be obtained
using various optimization techniques such as genetic

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Arabian Journal for Science and Engineering

algorithm, particle swam, ant colony and cuckoo search Figure  10a: https​: //anile​i 007-gmail​. tinyt ​a ke.com/sf/
which are suggested as future scopes of this research. MzQ0M​zMyMF​8xMDM​xNDIw​NA
Figure  10b: https​: //anile​i 007-gmail​. tinyt ​a ke.com/sf/
MzQ0M​zMyMV​8xMDM​xNDI3​Nw
Appendix 1 Figure  10c: https​: //anile​i 007-gmail​. tinyt ​a ke.com/sf/
MzQ0M​zMyNV​8xMDM​xNDI4​MQ
Considering the linearized system (17) in series with Ku , Figure 11a, b: https​://anile​i007-gmail​.tinyt​ake.com/sf/
apply first-order Pade approximation for delay term and put MzQ0M​zMyN1​8xMDM​xNDI5​NQ
the values from Table 1. yields (39): Figure 12a, b: https​://anile​i007-gmail​.tinyt​ake.com/sf/
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0.0045 1 − 0.1s
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s(0.0055s + 1) 1 + 0.1s
sf/MzQ0M​zMzNl​8xMDM​xNDMy​OQ
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(40) is obtained. MzQ0M​zMzN1​8xMDM​xNDMz​MA
( )
0.00055s3 + 0.1055s2 + 1 − 0.00045Ku s + 0.0045Ku = 0
(40)
Simplified (40), gives (41)
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