Abstract
Selecting the cutting data (cutting speed, feed, depth of cut) and the proper cutting tools play a significant role in achieving minimum production time, consistent quality and in controlling the overall cost of manufacturing. However, searching for a proper tool/insert-job combination calls for a huge amount of data and an extensive knowledge base and may take a long time and effort if it is done manually. In this paper, a software has been designed and established using Microsoft Visual Basic.Net and SQL server to store all different types of tool grades with their available cutting data, inserts, and tool holders for all materials and some machining operations (turning, drilling and milling) in a database. The software is capable of selecting the suitable cutting data, tool grade, insert and tool holders for each operation in two cases. The first case uses the maximum cutting speed of the tool grade (minimum tool life) while the second case uses the minimum cutting speed (maximum tool life). In the two cases, the software considers the constraints of power, efficiency, and maximum spindle revolution of the machine as well as the required surface roughness of the workpiece. The software is capable of calculating the machining time, intermittent time, force, torque, power, spindle revolution and total production time and cost for each operation. In addition, the workpiece material, required operations, cutting data, force, torque, power, the suitable tool grade and its manufacturer, insert and tool holder are displayed in a single report as a process sheet. Another report can be used to show the total production time and the total cost. A case study has been done to test the proposed software and it was found that about 34% of the total production time could be saved by using the maximum cutting speed, compared with the minimum cutting speed. On the other hand, about 28% of the total production cost could be saved by using the minimum cutting speed, compared with the minimum cutting speed.
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