Integrated optimization model for cutting data selection based on maximal MRR and tool utilization in continuous machining operations

Abstract The search for increased productivity can be interpreted as the increase of material removal rate (MRR). Namely, increase of feed, depth of cut and/or cutting speed. The increase of any of these three variables, will increase the tool wear rate; therefore decreasing its tool life according to the same tool life criteria. This paper proposes an integrated model for efficient selection of cutting data for maximal MRR and maximal tool utilization. The results show that, it is possible to obtain a limited range of cutting parameters from where the CAM Programmer can select the cutting data assuring both objectives.

[1]  F. W. Taylor.  The Art of Cutting Metals , 1907 .

[2]  Türkay Dereli,et al.  Dynamic optimization of multipass milling operations via geometric programming , 1999 .

[3]  Y. S. Tarng,et al.  Cutting-parameter selection for maximizing production rate or minimizing production cost in multistage turning operations , 2000 .

[4]  Anders Wretland,et al.  Analysis of Tool Utilization from Material Removal Rate Perspective , 2015 .

[5]  N. R. Dhar,et al.  Beneficial effects of cryogenic cooling over dry and wet machining on tool wear and surface finish in turning AISI 1060 steel , 2001 .

[6]  João Paulo Davim,et al.  Tools (Geometry and Material) and Tool Wear , 2008 .

[7]  A. Moufki,et al.  A review of developments towards dry and high speed machining of Inconel 718 alloy , 2004 .

[8]  Franci Cus,et al.  Optimization of cutting conditions during cutting by using neural networks , 2003 .

[9]  Neelesh Kumar Jain,et al.  Optimization of process parameters of mechanical type advanced machining processes using genetic algorithms , 2007 .

[10]  L. N. López de Lacalle,et al.  Prediction of specific force coefficients from a FEM cutting model , 2009 .

[11]  L. N. López de Lacalle,et al.  Advanced cutting conditions for the milling of aeronautical alloys , 2000 .

[12]  T. Obikawa,et al.  High speed MQL finish-turning of Inconel 718 with different coated tools , 2007 .

[13]  L. N. López de Lacalle,et al.  Influence of low-plasticity ball burnishing on the high-cycle fatigue strength of medium carbon AISI 1045 steel , 2013 .

[14]  Herman Jacobus Cornelis Voorwald,et al.  An evaluation of shot peening, residual stress and stress relaxation on the fatigue life of AISI 4340 steel , 2002 .

[15]  Wen-Tung Chien,et al.  The investigation on the prediction of tool wear and the determination of optimum cutting conditions in machining 17-4PH stainless steel , 2003 .

[16]  I. S. Jawahir,et al.  Metrics-based Sustainability Evaluation of Cryogenic Machining , 2015 .

[17]  Sounak Kumar Choudhury,et al.  Optimization of cutting parameters for maximizing tool life , 1999 .

[18]  Jun Wang,et al.  Optimization of Cutting Conditions for Single Pass Turning Operations Using a Deterministic Approach , 2002 .

[19]  L. N. López de Lacalle,et al.  Using High Pressure Coolant in the Drilling and Turning of Low Machinability Alloys , 2000 .

[20]  Wassila Bouzid,et al.  Cutting parameter optimization to minimize production time in high speed turning , 2005 .