Optimal Cutting Parameters for Turning Operations with Costs of Quality and Tool Wear Compensation (original) (raw)
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Calculation of optimum cutting conditions for turning operations
… : Proceedings of the …, 1985
The ever-increasing development and implementation of expensive advanced machines have made the study of machining economics increasingly important. Machining economics is to a great extent about making use of production resources most efficiently and at the lowest possible cost. Since the cost and time of machining are sensitive to the cutting conditions, optimum values have to be determined before a part is put into production. The optimum cutting conditions in this context are those that do not violate any of the constraints that may apply on the process and satisfy the economic criterion. The main objectives of this thesis are to investigate the methodologies and to develop a logical algorithm for predicting the constrained optimum cutting conditions in oblique machining with nose radius tools so that the production cost/time can be calculated and minimised. Based on a variable flow stress machining theory, a method has been developed for predicting cutting forces, stresses, temperatures, etc. which are then used to check process constraints such as machine power, tool plastic deformation and built-up edge formation, from a knowledge of the work material properties and the cutting conditions. 2.1 Optimisation Criteria, Constraints and Strategies 11 2.2 Analytical Studies of Machining Process 2.2.1 The Orthogonal Machining Theory 2.3 Oblique Machining with Nose Radius Tools 2.3.1 Chip Flow Direction and Equivalent Cutting Edge 2.3.2 Chip Flow Angle due to the Effect of Nose Radius 2.3.3 Modified Tool Angles and Equivalent Cutting Edge 40 2.4 Cutting Forces and Tool Temperatures in Oblique Machining Chapter Three. Modelling of the Optimisation of cutting conditions 3.1 Economic Consideration and Objective Functions of a Single-Pass Turning Operation 3.2 Optimisation Procedure 3.3 Constraints , iv 3.3.1 Tool Plastic Deformation 50 3.3.2 Machine Tool Torque/Power 51 3.3.3 Minimum and Maximum Tool Life Values 53 3.3.4 Available Feeds and Speeds of the Machine Tool Used, as well as the Minimum and Maximum Feeds/Depths for Tool and Workpiece 53 3.3.5 Built-up Edge Formation 54 3.4 Prediction of Cutting Forces, Temperatures, Stresses, etc. in Oblique Machining With Nose Radius Tools 56 3.5 Prediction of Tool Life in Oblique Machining 57 Chapter Four. Prediction of Cutting Conditions Giving Plastic Deformation of the Tools in Oblique Machining 59 4.1 Introduction 4.2 Review of Previous Work 4.3 Calculation of Stresses Inside the Cutting Edge of a Tool 4.3.1 Stress Analysis in the Cutting Edge region of a Tool 67 4.3.2 Stresses on the Tool Flank-Work Interface 71 4.4 Prediction of Cutting Conditions Giving Plastic Deformation of the Cutting Edge of a Tool 72 4.4.1 Loading Conditions of a Tool 4.4.2 Prediction Methodology 4.4.3 Comparison Between Predicted and Experimental Plastic Deformation Conditions in Approximately Orthogonal Machining 4.4.4 Prediction of Plastic Deformation Conditions in Oblique Machining 4.4.4.1 Determination of High Temperature Shear Strength Data for the Tool Material 4.4.4.2 The Predicted Results 4.5 Experimental Procedure 4.5.1 Methods Used for Determining Plastic Deformation
Calculation of optimum cutting conditions for turning operations using a machining theory
International Journal of Machine Tools and Manufacture, 2000
The ever-increasing development and implementation of expensive advanced machines have made the study of machining economics increasingly important. Machining economics is to a great extent about making use of production resources most efficiently and at the lowest possible cost. Since the cost and time of machining are sensitive to the cutting conditions, optimum values have to be determined before a part is put into production. The optimum cutting conditions in this context are those that do not violate any of the constraints that may apply on the process and satisfy the economic criterion.
Cutting parameter optimization to minimize production time in high speed turning
Journal of Materials Processing Technology, 2005
A method is described for calculating the optimum cutting conditions, in turning for objective criteria such as maximum production rate. The method uses empirical models for tool life, roughness and cutting forces. Coefficients of these models were determined based on turning experiments in high speed machining. Four types of commercially available inserts have been used to turn an AISI 4340 steel. Three chemical vapor deposition (CVD) coated inserts and one ceramic tool have been studied. In this work, the machine power and the maximum spindle speed were considered as the process constraints. The method consists on explaining the feed in relation to the roughness which depends on the cutting speed. Then, the cutting speed which gives the minimum production times was calculated. This value is then compared to the allowed values imposed by the constraints. At least, the optimal value of feed was calculated. The obtained results indicate that the described method is capable of selecting the appropriate conditions.
Advances in Production Engineering & Management, 2013
This paper implements a holistic decision approach for determining tool wear and surface quality together with machining parameters such as cutting speed, feed rate, depth of cut, and cutting passes during turning operations. As a consequence, two machining optimisation models are formulated with the objectives of maximising the material removal rate and minimising the production cost so that the decisions regarding machining parameters can be determined as well as the status of tool wear and surface quality between intermediate cutting passes. The feasibility and applicability of the formulated models have been tested through computational analyses, and a comparison made between the two performance objectives. The results show that the integrated decisions of machining parameters, tool wear and surface quality can be made and thus avoid the application of expensive on-line equipment for measuring tool wear and surface quality. Furthermore, the feasible removal of material during turning operations can be achieved through proper selection of depths of cut and number of cutting passes. The proposed optimisation models can also be used to provide tool replacement schedules based on the number of processing parts and cutting passes.
Optimization of Cutting Parameters of Tool Wear in Turning Operations: A Review
2021
Tool wear is one of the major factors that contribute to surface quality, productivity and accuracy in machining. It also determines production flow by increasing the number of shutdowns for tools reshaping. Tool wear is related to cutting process parameters (depth of cut, spindle speed and feed rate), the surface nature of the metal (scaly or smooth), the cutting forces and thermal condition at cutting zone. This paper present review of various works on optimizing the tool wear rate during turning operation. Also, it presents techniques used in monitoring the processes and methods of determining the rate of tool wear with their results in an orthogonal machining operation on different type of materials.
Design optimization of cutting parameters for turning operations 1
In this study, the Taguchi method, a powerful tool to design optimization for quality, is used to find the optimal cutting parameters for turning operations. An orthogonal array, the signal-to-noise (S/N) ratio, and the analysis of variance (ANOVA) are employed to investigate the cutting characteristics of S45C steel bars using tungsten carbide cutting tools. Through this study, not only can the optimal cutting parameters for turning operations be obtained, but also the main cutting parameters that affect the cutting performance in turning operations can be found. Experimental results are provided to confirm the effectiveness of this approach.
Optimization of Cutting Parameters in Turning Process
SAE International Journal of Materials and Manufacturing, 2014
Predicting the main cutting force during turning is of great importance as it helps in setting the appropriate cutting parameters before machining starts. Again, optimization of cutting parameters is one of the most important elements in any process planning of metal parts as economy of machining operation plays a key role in gaining competitive advantage. This paper presents an experimental study of main cutting force in turning of AISI 1040 steel and developing a model of the main cutting force during turning using Response surface Methodology (RSM) as well as optimization of machining parameters using Genetic Algorithm (GA). The second order empirical model of the main cutting force in terms of machining parameters have been developed based on experimental results. The experimentation has been carried out considering three machining parameters: cutting speed, feed rate and depth of cut as independent variables and the main cutting force as the response variable. The formulated model has been validated against new set of experimental values using Mean Absolute Percent Error (MAPE) method. The Genetic Algorithm approach is also used to optimize the cutting parameters to keep the main cutting force to a minimum.
Effective use of Cutting Parameters in Turning Process to Enhance Tool life
2017
Machining is the process of removing the excess material from the work piece or unwanted material from the work piece using a cutting tool. The surface finish and tool life obtain in machining process depends upon the various factors like work material, tool material , tool geometry, machine conditions, coolant and feed rate , speed , depth of cut etc. The focus of present study deals with finding optimal controlled process parameters to obtain good surface finish as well as here predicted tool life. It also shows the effect of the process parameters; cutting speed, feed rate and depth of cut on tool life. Experiments design and conducted based on Taguchi method and corresponding surface roughness were noted. The most affecting factor on tool life are cutting speed and feed observed after the experimentation. Here it is also concluded that tool life decreases with increases of cutting speed and feed in machining process for CNMG tool and grey cast iron work material combination.
2013
This research work focuses on precision turning of Ti6Al4V material to investigate the machinability of the material. Precision turning is a type of machining where, very low feed rate and depth of cut is being used to machine using a cutting insert with a lower nose radius. The cutting parameters considered for the experiments include the cutting speed, feed rate, depth of cut and nose radius. PVD coated carbide cutting inserts with different nose radius and constant rake and clearance angle are being considered for experimentation. The experimentation was designed based on Taguchi's L 27 orthogonal array. Three different levels of cutting parameters were being considered for the experimentation. The turning experiments were carried out on a conventional variable speed motor lathe under dry working conditions. Based upon the experimental values, Analysis of Variance (ANOVA) was conducted to understand the influence of various cutting parameters on cutting force, surface roughness chip morphology, tool wear and cutting tool temperatures during precision turning of titanium alloy. Optimal levels of parameters were identified using grey relational analysis and significant parameter was determined by analysis of variance. Experimental results indicate that multi-response characteristics.
Optimization of Process Parameters in Turning Operation – A Review
— Turning is the course of action in which a single point cutting tool removes needless material from the surface of a spinning cylindrical work piece This review paper discuss development in literature on optimisation of process parameters in turning action by studying the influence of different process parameters. The purpose of turning operation is to bring into being low surface roughness of the parts. There are three parameter which are studied, namely fee , depth of cut and spindle speed for the optimization and minimization of the surface roughness. To optimize the process parameters it's needed to determine which parameters are most important for required output because these quality features are highly linked and are expected to be subjective directly or in some way by the direct effect of process parameters. Optimization of surface roughness of turning is a multi-factor, multi objective optimization problem.