Parametric modelling and automatic optimisation of high-speed hard cutting process

In traditional finite element method (FEM) simulation model of cutting process, settings of material parameters and boundary conditions take up a lot of time. The optimal cutting parameters are not easily obtained by simulation results; also the target of solution process is blind. Based on optimisation theory and secondary development of finite element software, in this research, a parametric model is established by combining python with Abaqus for PCBN tool cutting steel orthogonally. Numerical values of tool angle, tool size, workpiece size and process can be set in the interface of two-dimensional model in a parameterised way. By combining Abaqus and Isight, the average value of cutting force and highest value of cutting temperature could be extracted from the simulation model automatically. To get the minimum of cutting force and temperature under the selected parameter, the model takes cutting feed and speed as design variables to optimise. Under experimental validation, the precision of optimisation results is acceptable. This research result lays a foundation for establishment of high efficiency and high accuracy FEM simulation model. Also, it provides a feasible and effective way for the optimisation of cutting parameters and development of new tools. [Received 09 November 2014; Revised 09 February 2015; Accepted 14 February 2015]