Abstract: In this work, an adaptive control constraint system has been developed for computer numerical control (CNC) turning
based on the feedback control and adaptive control/self-tuning control. In an adaptive controlled system, the signals from the online
measurement have to be processed and fed back to the machine tool controller to adjust the cutting parameters so that the machining
can be stopped once a certain threshold is crossed. The main focus of the present work is to develop a reliable adaptive control system,
and the objective of the control system is to control the cutting parameters and maintain the displacement and tool flank wear under
constraint valves for a particular workpiece and tool combination as per ISO standard. Using Matlab Simulink, the digital adaption
of the cutting parameters for experiment has confirmed the efficiency of the adaptively controlled condition monitoring system, which
is reflected in different machining processes at varying machining conditions. This work describes the state of the art of the adaptive
control constraint (ACC) machining systems for turning. AISI4140 steel of 150 BHN hardness is used as the workpiece material, and
carbide inserts are used as cutting tool material throughout the experiment. With the developed approach, it is possible to predict the
tool condition pretty accurately, if the feed and surface roughness are measured at identical conditions. As part of the present research
work, the relationship between displacement due to vibration, cutting force, flank wear, and surface roughness has been examined.
Keywords: Adaptive control, condition monitoring, model based control system and flank wear, surface roughness, displacement.