Material Removal Rate Control Research Articles

Material Removal Rate Control in Open-Air Type Plasma Chemical Vaporization Machining by Pulse Width Modulation of Applied Power

Plasma chemical vaporization machining (PCVM) is an ultraprecise figuring technique for optical components without introducing the subsurface damage. In our previous study, the material removal volume was controlled by changing the scanning speed of the worktable. However, because of inertia of the worktable, a discrepancy between the theoretical scanning speed and the actual scanning speed will occur if the spatial change rate of speed is rapid. Therefore, we proposed the application of the pulse width modulation (PWM) control and the amplitude modulation (AM) control of the applied RF power to control the material removal rate (MRR). Experimental results showed that the relationship between the MRR and the average RF power had high linearity, the control range of the PWM control mode was from 0.19 x 10-2 mm3/min to 3.90 x 10-2 mm3/min (from 5% to 100%), which was much wider than that of the AM control mode.

Experimental Study on Material Removal Rate for Engineering Ceramics Machining with Micro-Detonation of Striking Arc

The material removal rate (MRR) of micro-detonation of striking arc machining (MDSAM) is studied. The orthogonal experimental design and regression analysis method are employed to build the empirical model and the influencing laws of processing parameters on impact force are educed. Experimental results show that the material removal rate decreases with the increment of working distance and increases with the growth of working current, working gas pressure and pulse width. The exponential type empirical model with feature of simple and reliable consists with experiment results well. The research can offer an important reference for the predication and control of material removal rate in the process of micro-detonation machining of striking arc.

Dynamic MRR Function Optimization Using Calculus of Variations

A dynamic machining model to optimize the control of material removal rate (MRR) for a cutting tool undergoing the considerations of fixed tool life and maximum machining rate is established in this paper. This study not only applies material removal rate mathematically into the objective function, but also implements Calculus of Variations to comprehensively optimize the control of material removal rate. In addition, the optimal solution for the dynamic machining model to gain the maximum profit is provided, and the decision criteria for selecting the optimal solution of the dynamic machining model are then recommended. Moreover, the computerized analyses to simulate both the dynamic and traditional machining models for a numerical example are also promoted. This study definitely contributes an applicable approach to the dynamic function of material removal rate and provides the efficient tool to concretely optimize the profit of a cutting tool for operation planning and control in modern machining industry with profound insight.

Review of micromachining of ceramics by etching

In the last two decades, there has been an enormous surge in interest in ceramic materials and, as a result, there have been significant advances in their development and applications. Their inherent properties, such as capability of operating at temperatures far above metals, high level of hardness and toughness, low coefficient of thermal expansion and high thermal conductivity rendered ceramics to be one of the leading engineering materials. Many research works have been conducted in the past few years on machining of advanced ceramics using different processing methods in order to obtain a better surface roughness, higher material removal rate and improved tool life. Micromachining using chemical etching is one of those methods that do not involve the problem of tool life and direct tool–work piece contact. However, only a few research works have been done on micromachining of ceramics using chemical etching. Hence, study of chemical machining of advanced ceramics is still needed as the process has found wide application in the industry because of its relative low operating costs. In this work, we summarize the recent progresses in machining of different types of advanced ceramics, material processing methods such as wet etching and dry etching, and finally the prospects for control of material removal rate and surface quality in the process of ceramic micromachining.

The implementation of optimum MRR on digital PC-based lathe system

Optimizing the profit of an individual cutting tool is crucial to the computer numerically controlled (CNC) machining industry. In this paper, the mathematical modeling, the dynamic solution, and the decision criteria through calculus of variations are introduced to achieve the optimal material removal rate (MRR) control of a cutting tool under the fixed tool life. To realize the optimum MRR, a commercialized lathe system with a digital processor controller (DSP) and a man-machine interface is developed. Additionally, the implementation of dynamic MRR control for a real-world industrial case is experimentally performed on our proposed digital PC-based lathe system. It is found that the surface roughness (Ra) of all machined work-pieces not only stabilizes as the tool consumed, but also accomplishes the recognized standard for finish turning. In this study, the adaptability of the dynamic control of optimum MRR as well as the realization of the digital PC-based lathe system are absolutely guaranteed.

Electronic Circuit Simulation and Digital PC-Based Implementation of Dynamic MRR Optimization

Dynamic MRR (material removal rate) modeling is constructed and optimum solution through Calculus of Variations in maximize the machining profit of an individual cutting tool under fixed tool life is introduced. The mathematical model is formulated by reverse experiments on an ECOCA PC-3807 CNC lathe, and the electronic circuit is developed using linear regression technique for virtual machining. The inaccuracy between actual and simulated voltage is assured to be within 2%. By introducing a real-world CNC (computerized numerical control) machining case from AirTAC into the virtual system, the simulated cutting forces are shown to promise the feasible applicability of the optimum MRR control. Additionally, the implementation of dynamic solution is experimentally performed on a proposed digital PC-based lathe system. The surface roughness of all machined work-pieces is found to not only stabilize as the tool consumed, but also accomplish the recognized standard for finish turning.

An experimental approach of optimum material removal rate under fixed tool life

Optimizing the machining profit of an individual cutting tool has become critical to the computer numerical controlled (CNC) machining industry. In this paper, the mathematical modeling and the dynamic solution using calculus of variations to complete the optimal material removal rate (MRR) control of a cutting tool with a fixed tool life are introduced. Additionally, the advantage of this study is also demonstrated through a numerical illustration from the real-world industry with BORLAND C++ BUILDER. It is shown that the theoretical and simulated results are in good agreement. Moreover, the implementation of dynamic MRR control to analyze the numerical case is experimentally performed on the ECOCA PC-3807 CNC lathe. The surface roughness of all machined workpieces is found to not only stabilize as the tool consumed, but also reach the recognized standard for finish turning. With this study, the construction of dynamic MRR optimization for multi-operation and multi-tool CNC programs in achieving the maximum machining profit can be further advanced.

Optimum operation control for multiple machining projects under fixed production interval

The dynamic MRR control is the goal to optimize machining operations in the CNC machining systems. The concentration on the minimum-cost machining control with material removal rate (MRR) grows up in the computer-based machining industry. In this paper, the mathematical modeling with dynamic MRR control to minimize the machining cost as well as schedule the due-dates for multiple machining projects within a given production period is established. The optimum solution in manipulating the dynamic optimization task as well as the completeness and optimality of the solution are accomplished through Calculus of Variations. Moreover, the decision criteria for selecting the dynamic solution and the sensitivity analyses for key variables in the optimal solution are fully discussed. This study exactly explores the very promising solution to not only dynamically motivate the MRR in minimizing the machining cost, but also comprehensively schedule the due-dates for multiple machining quantities within a deterministic production period for both machine tool manufacturers and operations researchers.

OPTIMUM MRR CONTROL AND PRODUCTION DUE-DATE ASSIGNMENT FOR MULTIPLE MACHINING PROJECTS IN A DETERMINISTIC INTERVAL

ABSTRACT The concentration on the minimum-cost machining control with material removal rate (MRR) grows up in the computer-based machining industry. In this paper, the mathematical modeling with dynamic MRR control to minimize the machining cost and assign the due-dates for multiple machining projects within a given production period is established. The optimum solution as well as the completeness and optimality of the solution are accomplished through Calculus of Variations. Additionally, the decision criteria for selecting the dynamic solution and the sensitivity analyses for key variables in the optimal solution are fully discussed. Moreover, the numerical example from real-world industrial is introduced to demonstrate the advantages of this study. The dynamic MRR control is the goal to optimize machining operations in the CNC machining systems. This study exactly explores the very promising solution to not only dynamically manipulate the MRR in minimizing the machining cost, but also comprehensively determine the due-dates for multiple machining quantities within a deterministic production period for both machine tool manufacturers and operations researchers.

OPTIMAL MACHINING PROJECT CONTROL WITH MATERIAL REMOVAL RATE

A MPC, Machining Project Control, Model to achieve the optimal control of material removal rate (MRR) for a machining project undergoing the considerations of project quantity and production period is established in this study. This paper not only applies material removal rate into the objective function mathematically, but also implements Calculus of Variations to resolve the dynamic control problem comprehensively. In addition, the optimal solution for the control of material removal rate is proposed and the decision criteria for selecting the optimal solution are recommended. Moreover, the sensitivity analyses for decision variables of the optimal solution are fully discussed. This study definitely contributes an efficient tool to control a machining project for manufacturing engineers with profound insight of today’s machining industry.

The optimal control of material removal rate with fixed tool life and speed limitation

A material removal control (MRC), model to achieve the optimal cutting rate control of a cutting tool during machining is established in this study, which can direct a project towards reaching maximal profit. This paper not only applies the material removal rate (MRR) into the objective function mathematically, but also implements the calculus of variations to resolve the cutting rate control problem comprehensively. In addition, a dynamic solution for the control of the MRR is proposed and the decision criteria for selecting the optimal solution are recommended. Moreover, the sensitivity analyses for decision variables of the optimal solution are discussed. This study provides an efficient tool for controlling the machining rate for production engineers in present-day manufacturing.

DYNAMIC MACHINING PROJECT CONTROL MODEL UNDER ORDER QUANTITY AND DEADLINE CONSTRAINTS

To achieve the optimal control of material removal rate (MRR) for a machining project, a Dynamic Machining Project Control (DMPC) Model is proposed under the considerations of order quantity and deadline constraints. This paper not only introduces material removal rate into the objective function dynamically, but also implements Calculus of Variations to resolve the continuous control problem comprehensively. In addition, the optimal solution to minimize the cost of a machining project with production deadline is provided, and the decision criteria for selecting the optimal solution are recommended. Moreover, the sensitivity analyses of decision variables in the optimal solution as well as the numerical simulation of a real industrial problem are fully discussed. This study contributes a significant approach to control a machining project for production engineers in today's machining industry with profound insight.

A computerized decision tool to optimize tool life for maximal profit

A DMR, Dynamic Material Removal, Model to reach the optimal control of material removal rate (MRR) for a cutting tool undergoing the considerations of fixed tool life and maximal cutting rate is proposed in this paper. This study not only mathematically introduces material removal rate into the dynamic machining model, but also implements Calculus of Variation to optimize the dynamic control for material removal rate. In addition, the comparison to the traditional machining model is fully discussed. Moreover, the computerized decision tool to determine the optimal machining model and tool life for maximal profit is comprehensively presented. This study definitely contributes a reliable aspect to control the machining operation, and establishes an applicable tool to select the optimal machining model for production engineers in today’s manufacturing with profound insight.