Optimization of Cutting Conditions for Multi-Pass Operations Considering Probabilistic Nature in Machining Processes

1977 ◽  
Vol 99 (1) ◽  
pp. 210-217 ◽  
Author(s):  
K. Iwata ◽  
Y. Murotsu ◽  
F. Oba
Keyword(s):  
Dynamic Programming ◽  
Stochastic Programming ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Optimum Cutting ◽  
The Cost ◽  
Probabilistic Nature ◽  
Number Of Passes

This paper deals with the problem of optimizing the number of passes required together with the cutting speed, the feed, and the depth of cut at each pass for a given total depth of cut to be removed from a workpiece, considering both the probabilistic nature of the objective function and the constraints in the machining processes. Applying the concept of dynamic programming and stochastic programming, the problem is formulated in an analytically tractable form and a new algorithm is developed for determining the optimum value of the cutting speed, feed, depth of cut, and number of passes, simultaneously. For illustration, a typical example is solved to obtain the cost-minimizing cutting conditions in a turning operation, and the effect on the optimum cutting conditions of the various factors such as total depth of cut, uncertainty of the tool life, and constraints are discussed.

A Probabilistic Approach to the Determination of the Optimum Cutting Conditions

1972 ◽  
Vol 94 (4) ◽  
pp. 1099-1107 ◽  
Author(s):  
K. Iwata ◽  
Y. Murotsu ◽  
T. Iwatsubo ◽  
S. Fujii
Keyword(s):  
Analytical Method ◽  
Production Cost ◽  
Probabilistic Approach ◽  
Cutting Conditions ◽  
Chance Constrained Programming ◽  
Optimum Cutting ◽  
Constrained Programming ◽  
The Cost ◽  
Probabilistic Nature

An analytical method applying a chance-constrained programming concept is proposed to determine the optimum cutting conditions considering the probabilistic nature of the objective function and constraints. The proposed analytical method is illustrated through an application to an example. It is shown that the optimum cutting conditions are significantly affected by the probabilistic nature of coefficients in the constraints. The effect of the uncertainty of the predicted tool life in the production cost function on the optimum cutting conditions is also considered. The study further investigates the effects of the cost-time parameter and allowable maximum force on the optimum conditions and the resulting production cost.

Life Prediction of Cutting Tool by the Workpiece Cutting Condition

2011 ◽  
Vol 223 ◽  
pp. 554-563 ◽  
Author(s):  
Noemia Gomes de Mattos de Mesquita ◽  
José Eduardo Ferreira de Oliveira ◽  
Arimatea Quaresma Ferraz
Keyword(s):  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Operating Conditions ◽  
Production Costs ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Workpiece Material ◽  
The Cost

Stops to exchange cutting tool, to set up again the tool in a turning operation with CNC or to measure the workpiece dimensions have direct influence on production. The premature removal of the cutting tool results in high cost of machining, since the parcel relating to the cost of the cutting tool increases. On the other hand the late exchange of cutting tool also increases the cost of production because getting parts out of the preset tolerances may require rework for its use, when it does not cause bigger problems such as breaking of cutting tools or the loss of the part. Therefore, the right time to exchange the tool should be well defined when wanted to minimize production costs. When the flank wear is the limiting tool life, the time predetermination that a cutting tool must be used for the machining occurs within the limits of tolerance can be done without difficulty. This paper aims to show how the life of the cutting tool can be calculated taking into account the cutting parameters (cutting speed, feed and depth of cut), workpiece material, power of the machine, the dimensional tolerance of the part, the finishing surface, the geometry of the cutting tool and operating conditions of the machine tool, once known the parameters of Taylor algebraic structure. These parameters were raised for the ABNT 1038 steel machined with cutting tools of hard metal.

Experimental Investigation on Turning of Monel K500 Alloy Using Nano Graphene Cutting Fluid Under Minimum Quantity Lubrication

2019 ◽  
Author(s):  
Arul Kulandaivel ◽  
Senthil Kumar Santhanam
Keyword(s):  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
High Strength ◽  
High Heat ◽  
Water Soluble ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Turning Operation ◽  
Minimum Quantity

Abstract Turning operation is one of the most commonly used machining processes. However, turning of high strength materials involves high heat generation which, in turn, results in undesirable characteristics such as increased tool wear, irregular chip formation, minor variations in physical properties etc. In order to overcome these, synthetic coolants are used and supplied in excess quantities (flood type). The handling and disposal of excess coolants are tedious and relatively expensive. In this proposed work, Water Soluble Cutting Oil suspended with nanoparticles (Graphene) is used in comparatively less quantities using Minimum quantity lubrication (MQL) method to improve the quality of machining. The testing was done on Turning operation of Monel K500 considering the various parameters such as the cutting speed, feed and depth of cut for obtaining a surface roughness of 0.462μm and cutting tool temperature of 55°C for MQL-GO (Graphene oxide) process.

Machining Conditions Effect to Machining Temperature and Forces in Orthogonal Machining of Bone

2013 ◽  
Vol 658 ◽  
pp. 223-226 ◽  
Author(s):  
Denni Kurniawan ◽  
N. Jiawkok ◽  
M.Y. Noordin
Keyword(s):  
Analytical Study ◽  
Cutting Speed ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Allowable Limit ◽  
Machining Conditions ◽  
Orthogonal Machining ◽  
Dental Implantation ◽  
Cutting Direction

Bone machining processes are often performed in orthopaedic surgery and dental implantation, yet its analytical study is lacking. Towards contributing analysis on bone machining, this study reviews available references on orthogonal machining of bones. Considering the allowable limit in temperature and duration during bone machining to avoid thermal necrosis, machining temperature and forces are the machining responses of interest. Machining conditions (cutting speed, depth of cut, cooling method, tool geometry, and cutting direction) are analyzed in term of their effect to those machining responses.

Dry Machining of Brass Using Titanium Carbonitride (TiCN) Coated Tool

2013 ◽  
Vol 372 ◽  
pp. 495-500
Author(s):  
Tasnim Firdaus Ariff ◽  
Mohd Syahidan Kamarudin ◽  
Mohd Amiruddin Haron
Keyword(s):  
Tool Wear ◽  
Temperature Rise ◽  
Cutting Parameters ◽  
Titanium Carbonitride ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Machining ◽  
Wear Rates ◽  
Optimum Cutting ◽  
The Cost

Dry machining is environmentally friendly, clean and safe to be performed. Regardless of decreasing tool life due to lack of lubricants, choosing dry machining over wet machining may be a wiser choice since the cost of purchasing and disposing the cutting fluids can contribute to a higher cost. Wear rates, tool wear intensities and material removal rates (MRR) of TiCN coated tools using both dry and traditional wet machining on brass were studied with the aim in finding the optimum cutting condition from four different cutting speeds (207, 279, 372 and 498 m/min) with two sets of cutting parameters; depth of cut and feed rate (d = 0.1 mm, f = 0.2 mm/rev and d = 0.2 mm, f = 0.4 mm/rev). Temperatures at the tool-chip interface were measured to analyze the effects of temperature rise during dry machining. Cost analysis on machining cost per piece between dry and wet machining was performed. The optimum cutting condition for wet and dry machining of brass using TiCN coated cutting tool was found to be 498 m/min at d = 0.2 mm, f = 0.4 mm/rev. The tool tip temperature obtained from dry machining did not influence tool wear since the temperature rise is quite similar to the wet machining temperatures. The machining for the dry machining reduced to about 25-76% per piece when compared with wet machining.

Fundamental Experiment of Near-Dry Deep Hole Drilling with BTA Tool - The Optimal Cutting Conditions and Tool’s Geometry

2012 ◽  
Vol 523-524 ◽  
pp. 109-112
Author(s):  
Fukuhito Nagata ◽  
Koji Akashi ◽  
Daisaku Ishibashi
Keyword(s):  
Cutting Speed ◽  
Cutting Conditions ◽  
Hole Drilling ◽  
Cutting Condition ◽  
Deep Hole ◽  
Deep Hole Drilling ◽  
Environmental Destruction ◽  
Optimum Cutting ◽  
Cutting Experiments ◽  
Fundamental Experiment

The BTA tool is a tool for deep-hole drilling. The deep-hole which be machined by this tool has the excellent straightness and roughness. However, it's use a lot of cutting oil. Therefore, it will lead to environmental destruction. Thereupon, in this study, it is applied the near-dry system to the deep-hole drilling with BTA tool. In the previously, it was designed the experimental device with a double tube system, and the cutting experiments was carried out. In this system, the chip is discharged through inside of the inner tube. Frequently, the chip is cannot be divided by the adhesion on the cutting edge during drilling. Thereby, the chip was jammed into the inside of tool’s tube. It is tried experiments of various cutting conditions, cutting speed and feed rate, by tools with different geometry, height and width, of the chip-breaker. And, it is observed the discharge condition of chips, the chip’s shape and the situation of adhesion. As a result, it can be found the optimum cutting condition and tool’s geometry for a continuous chip’s discharge while the deep-hole is drilling by a BTA tool in near-dry system.

Manufacturing Accuracy when Drilling Holes in Stainless Austenitic Steels DIN 1.4301

2013 ◽  
Vol 420 ◽  
pp. 250-253 ◽  
Author(s):  
Jozef Jurko
Keyword(s):  
Stainless Steels ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Austenitic Steels ◽  
Depth Of Cut ◽  
Surface Accuracy ◽  
Cutting Zone ◽  
Manufacturing Accuracy

This article presents the results of experiments that concerned on the surface accuracy by drilling of a Stainless steels 1.4301. This article presents conclusions of machinability tests on a Stainless steels 1.4301. The results of cutting zone evaluation under cutting conditions (cutting speed in interval vc=50-100 m/min, depth of cut ap=2.75 mm and feed f=0.01-0,8 mm per rev.).

scholarly journals Performance of Near Dry Hard Machining Through Pressurised Air Water Mixture Spray Impingement Cooling Environment

2019 ◽  
Vol 16 (1) ◽  
pp. 6108-6133
Author(s):  
R. Kumar ◽  
A.K. Sahoo ◽  
P.C. Mishra ◽  
R.K. Das
Keyword(s):  
Tool Life ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Interface Temperature ◽  
Depth Of Cut ◽  
Water Mixture ◽  
Impingement Cooling ◽  
Aisi D2 ◽  
Spray Impingement

The present paper emphasizes on experimental investigation, mathematical modelling, optimisation, tool life and cost analysis during machining of AISI D2 (heat treated) (55±1 HRC) steel using uncoated carbide tool through a novel method under spray impingement cooling environment. Taguchi based L16 orthogonal array was utilised to conduct the experiments. Analysis of variance with 95% confidence level shows that the feed and depth of cut, are the most compelling factor towards surface roughness as well as chip reduction coefficient whereas cutting speed is the utmost compelling feature associated to flank wear as well as chip-tool interface temperature. Optimised result is identified as v1-f1-d1 (machining speed of 63 m/min; cutting feed of 0.04 mm/rev and depth of cut of 0.1 mm) based on grey relational analysis and tool life is found to be 15 minutes at optimised cutting conditions. Flank wear due to abrasion, catastrophic failure due to diffusion, chipping and notch wear are noticed as the major tool wear mechanisms in hard turning. Mathematical machinability models show statistically significance because due to the superior coefficient of correlations. As the global machining cost for each part is less, uncoated carbide tools can machine effectively, efficiently and economically at optimum cutting conditions under spray environment.

scholarly journals INVESTIGASI VARIASI KECEPATAN POTONG OPTIMAL PADA PROSES PEMESINAN BAJA AISI 4140

POROS ◽  
2018 ◽  
Vol 16 (1) ◽  
Author(s):  
Sobron Yamin Lubis
Keyword(s):  
Cutting Tools ◽  
Cutting Speed ◽  
Machining Process ◽  
Aisi 4140 Steel ◽  
Maximum Production ◽  
Aisi 4140 ◽  
Optimum Cutting ◽  
Production Quantity ◽  
The Cost

Determination of optimum cutting speed in the lathe process should be considered in order to produce minimal machining costs and maximum production. Research The determination of optimum cutting speed was done to investigate the effect of cutting speed when cutting AISI 4140 steel against cost and production obtained. This study was conducted experimentally using lathe and theoretical calculations to determine machining costs and the amount of production produced. The lathe process is carried out using carbide cutting tools for cutting of AISI 4140 steel metal. In this machining the data obtained is the cutting time of the machining process tail loading process then the data is incorporated into the equation together with the cutting force, the cost of the cutting tools, the workpiece, the cost labourers. Then from the calculation results obtained by graph machining cost and production amount. Based on the graph, it is observed minimal machining cost and maximum production amount to know the optimum cutting point. The results obtained .The increase in cutting rate gives effect to the increase of production quantity, while for calculation of machining cost has decreased. Machining time has a significant effect on the change of production quantity and machining cost. The optimal cutting speed (Vcopt) is 269 m / min.

scholarly journals Machining Process for a Thin-Walled Workpiece Using On-Machine Measurement of the Workpiece Compliance

2019 ◽  
Vol 13 (5) ◽  
pp. 631-638 ◽  
Author(s):  
Takuma Umezu ◽  
◽  
Daisuke Kono
Keyword(s):  
Measurement System ◽  
End Milling ◽  
Numerical Control ◽  
Cutting Conditions ◽  
Machining Process ◽  
Experimental Result ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Workpiece Vibration ◽  
Thin Walled

Demand for highly productive machining of thin-walled workpieces has been growing in the aerospace industry. Workpiece vibration is a critical issue that could limit the productivity of such machining processes. This study proposes a machining process for thin-walled workpieces that aims to reduce the workpiece vibration during the machining process. The workpiece compliance is measured using an on-machine measurement system to obtain the cutting conditions and utilize the same for suppressing the vibration. The on-machine measurement system consists of a shaker with a force sensor attached on the machine tool spindle, and an excitation control system which is incorporated within the machine tool’s numerical control (NC). A separate sensor to obtain the workpiece displacement is not required for the estimation of the displacement. The system is also capable of automatic measurement at various measurement points because the NC controls the positioning and the preloading of the shaker. The amplitude of the workpiece vibration is simulated using the measured compliance to obtain the cutting conditions for suppressing the vibration. An end milling experiment was conducted to verify the validity of the proposed process. The simulations with the compliance measurement using the developed system were compared to the results of a conventional impact test. The comparison showed that the spindle rotation speed for suppressing the vibration could be successfully determined; but, the axial depth of cut was difficult to be determined because the simulated vibration amplitude was larger than that found in the experimental result. However, this can be achieved if the amplitude is calibrated by one machining trial.

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