Optimization and graphical representation of machining conditions in multi-pass turning operations

Abstract This paper describes a procedure to calculate the machining conditions, such as the cutting speed, feed rate and depth of cut for turning operations with minimum production cost or the maximum production rate as the objective function. The optimum number of machining passes and the depth of cut for each pass is obtained through the dynamic programming technique and optimum values of machining conditions for each pass are determined based on the objective function criteria by search method application to the feasible region. Production cost and production time values are determined for different workpiece and tool material for the same input data. In the optimization procedure, the objective functions are subject to constraints of maximum and minimum feed rates and speeds available, cutting power, tool life, deflection of work piece, axial pre-load and surface roughness. By graphical representation of the objective function and the constraints in the developed software, the effects of constraints on the objective function can be evaluated. The parameters that are assumed to be most effective in determining the optimum point can easily be changed and the revised graph can be inspected for possible improvements in the optimum value.

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