Cutting Rate-Tool Life Characteristic Functions for Material Removal Processes—Part 1: Theory

1976 ◽  
Vol 98 (2) ◽  
pp. 481-486 ◽  
Author(s):  
M. Y. Friedman ◽  
V. A. Tipnis
Keyword(s):  
Tool Life ◽  
Material Removal ◽  
Characteristic Curve ◽  
Geometric Interpretation ◽  
Characteristic Functions ◽  
Economic Optimization ◽  
Profit Rate ◽  
Comprehensive Development ◽  
Cutting Rate ◽  
Removal Processes

The existence of cutting rate-tool life (R-T) characteristic functions for material removal operations is introduced in this paper. This new concept enables a comprehensive development of a theory for economic optimization encompassing commonly used criteria of cost, production rate, and profit rate in machining when more than one cutting variable is involved. The theory provides conditions for the existence of economic optima, all of which must lie on the R-T characteristic curve for a given operation. The analysis of the theory is carried out for one and two independent cutting variables. For these two cases, it is proven that the locus of the tangent points of constant cutting rate and constant tool life curves describes the R-T characteristic curve, and also that the tool life is maximum along a given constant cutting rate curve at the point of tangency and vice versa. This geometric interpretation provides useful application of the concept as shown in Part 2.

Cutting Rate-Tool Life Characteristic Functions for Material Removal Processes—Part 2: Verification and Applications

1976 ◽  
Vol 98 (2) ◽  
pp. 487-495 ◽  
Author(s):  
V. A. Tipnis ◽  
M. Y. Friedman
Keyword(s):  
Tool Life ◽  
Material Removal ◽  
The Other ◽  
Characteristic Functions ◽  
Designed Experiments ◽  
Cutting Rate ◽  
Removal Processes ◽  
T Domain ◽  
Economic Selection ◽  
Selection Of

The experimental verification, interpretations, and applications of the concept of cutting rate-tool life (R-T) characteristic functions are presented in this paper. Two statistically designed experiments, one on sawing and the other on milling, verifying the concept are described. The analytical and geometrical interpretations of the concept, including the existence of optima in the R-T domain, are presented. The applications discussed include economic selection of machining conditions, economic tool life determinations, comparison of machining response, objective function for adaptive control, and maximization of material removal at a desired level of surface integrity. The concept can be applied to other machining responses of conventional as well as nontraditional material removal processes.

Constrained Cutting Rate-Tool Life Characteristic Curve, Part 2: Convex Programs

1998 ◽  
Vol 120 (1) ◽  
pp. 160-165 ◽  
Author(s):  
C. L. Hough ◽  
Y. Chang
Keyword(s):  
Sensitivity Analysis ◽  
Tool Life ◽  
Simplex Method ◽  
End Milling ◽  
Characteristic Curve ◽  
Convex Programs ◽  
Machining Economics ◽  
Cutting Rate ◽  
Primal Dual ◽  
Simplex Tableau

Based on the concept in Part 1, Theory and General Case, algorithms to determine the constrained R-T characteristic curve are established for convex constrained machining economics problems. The first algorithm is for posynomial problems with the linear-logarithmic tool life equation. The R-T curve may be determined by applying the simplex method to the log-dual problems. Sensitivity analysis of the optimal simplex tableau enables obtaining the loci of optima easily. The second algorithm is for the quadratic posylognomial problems with quadratic-logarithmic tool life equation using the property of primal-dual feasibility. End milling examples constructed in Part 1 illustrate the algorithm comparing to the exhaustive method.

Constrained Cutting Rate-Tool Life Characteristic Curve, Part 1: Theory and General Case

1998 ◽  
Vol 120 (1) ◽  
pp. 156-159 ◽  
Author(s):  
C. L. Hough ◽  
Y. Chang
Keyword(s):  
Tool Life ◽  
Characteristic Curve ◽  
Sufficient Conditions ◽  
Global Optimum ◽  
Optimal Parameters ◽  
Constraint Equations ◽  
Machining Economics ◽  
Life Model ◽  
Cutting Rate ◽  
Necessary And Sufficient

The concept of a cutting rate-tool life (R-T) characteristic curve is extended to the general machining economics problem (MEP) with a quadratic-logarithmic tool life and constraint equations. The R-T characteristic curve presents the general loci of optima, which is useful in selecting optimal parameters for multiple machining conditions. The necessary and sufficient conditions for the global optimum of the unconstrained MEP are presented. These conditions are equivalently applied to the concept of the constrained R-T characteristic curve. In terms of quadratic geometric programming the objective function and constraints of the general MEP are called as quadratic posylognomials (QPL). The QPL problems are classified as convex and nonconvex and the convexity is determined by the second order terms of the tool life model. Nonlinear programming and an exhaustive method are demonstrated to determine the R-T characteristic curve for three cases of posynomial, convex QPL, and non-convex QPL problems.

scholarly journals A molecular dynamics based digital twin for ultrafast laser material removal processes

2020 ◽  
Vol 108 (1-2) ◽  
pp. 413-426 ◽  
Author(s):  
Panagiotis Stavropoulos ◽  
Alexios Papacharalampopoulos ◽  
Lydia Athanasopoulou
Keyword(s):  
Molecular Dynamics ◽  
Material Removal ◽  
Ultrafast Laser ◽  
Laser Material ◽  
Digital Twin ◽  
Removal Processes

scholarly journals Improvement of Machining Processes: A Case Study

2019 ◽  
Vol 2 (3) ◽  
pp. 634-641
Author(s):  
Hakan Gökçe ◽  
Ramazan Yeşilay ◽  
Necati Uçak ◽  
Ali Teke ◽  
Adem Çiçek
Keyword(s):  
Material Removal ◽  
Current Practice ◽  
Complex Geometry ◽  
Vital Role ◽  
Machining Process ◽  
Machining Processes ◽  
Machining Time ◽  
Machining Strategy ◽  
Removal Processes

In material removal processes, determination of optimal machining strategy is a key factor to increase productivity. This situation is gaining more importance when machining components with complex geometry. The current practice in the determination of machining strategy mostly depends on the experience of the machine operator. However, poorly designed machining processes lead to time-consuming and costly solutions. Therefore, the improvement of machining processes plays a vital role in terms of machining costs. In this study, the machining process of a boom-body connector (GGG40) of a backhoe loader was improved. Improvements of toolpaths and cutting conditions of 22 different material removal processes were checked through a CAM software. According to the simulation results, the process plan was rearranged. Besides, some enhancements in casting model were conducted to decrease in the number of machining operations. When compared to current practice, a reduction of 55% in machining time was achieved.

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