Process-controlled machining of gray cast iron

Abstract

Prior research (ref. 1) reported a model to predict surface roughness for specified values of cutting tool nose radius, feed rate, cutting speed and tool wear. The model is based on experimental data from finish turning of gray cast iron using uncoated tungsten carbide inserts. The results suggest that feed rate and cutting speed can be modified to produce a specified surface roughness in the presence of increasing levels tool wear. The method used in the paper to calculate values of feed rate and cutting speed is based on a multiple objective goal programming optimization scheme. The method predicts optimal machining conditions under the conflicting objectives of maximal production rate and minimal cost, subject to realistic constraints imposed by the capability of the machine tool and restrictions on the process parameters. Further adjustment of the cutting parameters is then made based on specified values of surface roughness and levels of tool wear.