Optimization Of Cutting Conditions Research Articles

Present Status and Future Directions of High Performance Cutting in Aerospace Manufacturing

Manufacturing remains the largest and most important wealth generating sector. Within this sector, material cutting is a key technology in the aerospace and automotive industries, contributing to more than C$200 billion to the economy in North America on annual basis. The demand for high productivity and high accuracy is steadily increasing, along with the increasing attention to the impact on the environment. With more than 700 companies in the aerospace sector, Canada has been ranked third globally in terms of global civil aircraft production, especially for aerostructures, providing more than C$27 billion of direct revenue annually. It is clear that improvement and optimization of metal cutting processes are essential for continuous improvement in this sector. This paper presents the recent advances in high-performance cutting technologies that are aligned with the I4.0 paradigm through featuring environmental and economical sustainability, effective digital inter-connectivity and integrated intelligence. The focus in this paper is placed on the following enabling technologies: (i) Superabrasive grinding using diamond and Cubic Boron Nitride (CBN) abrasives for grinding difficult-to-cut aerospace materials. (ii) Integrated process of laser-assisted machining (LAM) and laser surface heat treatment. (iii) New sustainable hybrid cooling using liquid nitrogen (LN2) with minimum quantity lubrication (MQL). (iv) Intelligent tool condition monitoring (TCM) to predict and prevent tool failure. (v) Virtual machining for tool geometry and cutting conditions optimization in drilling of fiber reinforced polymers (FRPs) and hybrid stacks.

Research Design and Identification of the Project Methodology Solutions Using the Finite Element Method

The anticipation of the process variables (temperature, cutting forces, and stress distribution) plays an important role in the tool geometry design and cutting conditions optimization. The researchers found that the anticipation of these variables experimentally is costly both from a time requirement and financial point of view. Having this information, the finite element model becomes the most favourable alternative and most useful in all aspects. Existing Empirical models are very useful in demonstrating these matters, but if tests have not been carried out to create these models types, then it brings benefits in the improvement specifically to the process itself. This paper is focus to conduct the research and discover a methodical design solution based on the finite element method. This entails defining the input data used within the research framework, including: application type, finite element analysis, material model, and, of course, choosing the process parameters. After determining the input data, following the completion of the theoretical models of the experiment, respecting the finite element model, the output will take into account the final results of the selected research. In order to obtain optimal solutions and to increase the precision and accuracy of the obtained results, it is necessary to validate this using the experiment.

Механообработка композиционного материала с использованием робототехнического комплекса на базе робота KUKA KR210

The purpose of this work is to improve the quality of surface and accuracy of holes and edges at machining of carbon fiber reinforced composite material by cutting conditions optimization. The robotic complex based on the KUKA KR210 R2700 EXTRA industrial robot was chosen as the main processing equipment. The object of the study is a carbon fiber plate of IMS 24K / PRISM EP 2400RS brand with the thickness of 16 mm. Drilling was performed with a CoroDrill 856-1-0635-05-A0 drill bit made by Sandvik Coromant with the diameter of 6.35 mm. This tool is a solid carbide drill with N20C diamond coating used for drilling high quality holes in composite materials. The milling operation was carried out using a 67-084 1/4 SC FGR milling cutter (Aramid) manufactured by Onsrud. The tool is a coating-free solid carbide cutter used for processing composite materials. The tests included the determination of cutting modes ensuring maximum performance, and the modes for maximum surface quality and accuracy of holes and edges. As part of the tests, the range of values of cutting conditions was chosen. It included the modes recommended by the tool manufacturer. At the end of the works, the roughness of holes and edges was measured using a Taylor Hobson Form Talysurf i200 contact profilometer. Hole diameters were controlled using the Carl Zeiss CONTURA G2 coordinate measuring machine. The dependences of the parameters of obtained roughness on the processing modes have been revealed. The graphs reflecting the variations of roughness and diameters depending on the cutting modes have been plotted as well as the graphs of cutting condition influence on edge surface roughness. Recommendations have been given on the application of composite material machining technologies on an industrial robot.

Analysis of Cutting Force Components in Hard Turning of AISI4340 Steel with Coated Carbide Tool: Regression Model and Cutting Conditions Optimization

Analysis of Cutting Force Components in Hard Turning of AISI4340 Steel with Coated Carbide Tool: Regression Model and Cutting Conditions Optimization

Multipass Turning Operation Process Optimization Using Hybrid Genetic Simulated Annealing Algorithm

For years, there has been increasing attention placed on the metal removal processes such as turning and milling operations; researchers from different areas focused on cutting conditions optimization. Cutting conditions optimization is a crucial step in Computer Aided Process Planning (CAPP); it aims to select optimal cutting parameters (such as cutting speed, feed rate, depth of cut, and number of passes) since these parameters affect production cost as well as production deadline. This paper deals with multipass turning operation optimization using a proposed Hybrid Genetic Simulated Annealing Algorithm (HSAGA). The SA-based local search is properly embedded into a GA search mechanism in order to move the GA away from being closed within local optima. The unit production cost is considered in this work as objective function to minimize under different practical and operational constraints. Taguchi method is then used to calibrate the parameters of proposed optimization approach. Finally, different results obtained by various optimization algorithms are compared to the obtained solution and the proposed hybrid evolutionary technique optimization has proved its effectiveness over other algorithms.

An Economical Approach to Stop an Experimental Campaign with the Aim of Reducing Cost

Nowadays, in a period of stagnation and economic crisis, the continuous improvement of the production technologies in order to optimize economic, energetic and productive resources is crucial. The increase in efficiency, measured in terms of cost reduction, is therefore a key problem that requires the attention of more and more companies and researchers. In particular, the productivity of a machining system and its related costs depend on the setup of the machining parameters. This choice plays a key role when the machining material is expensive, the production batch has a limited size and the tool to be used is new: typical examples are the aircraft and die/mold industries.In order to optimally setup a machine, the study of the tool life according to the material and the machining parameters is critical. The expression of the tool life could be estimated using an appropriate experimental campaign, which should have a limited size in order to reduce the experimental costs. This approach becomes of primary importance when the production is not in series where the costs can be spread over a large number of pieces.The aim of this paper is to propose a new methodology that stops the experimental campaign as soon as the expected gain in carrying on the experimentation does not justify the marginal cost of experimentation.To prove our idea, a simple problem from the well-known turning cutting condition optimization is used and the optimization technique Response Surface Methodology is selected.

Investigation and modeling of cutting forces and surface roughness when hard turning of AISI 52100 steel with mixed ceramic tool: cutting conditions optimization

The increasing industrial demand for hard materials and their wide range of applications requires significant investigations to improve their machinability. Therefore, the current study addresses cutting forces and surface roughness during hard turning of AISI 52100 steel (59 hardness Rockwell C (HRC)) using ceramic tool. Turning experiments were held out by varying cutting speed, depth of cut, feed rate, and tool nose radius. For so doing, a central composite design (CCD) was adopted including 30 tests. Cutting forces and surface roughness were modeled using response surface methodology (RSM). The effects of each input parameter on output responses were investigated using analysis of variance (ANOVA) and response surface graphics. The findings of this study demonstrated that the force components were significantly influenced by depth of cut, followed by feed rate with a lower degree. Likewise, the negative result of the small undeformed chip thickness on surface roughness was reduced by the employment of large nose radius. Conclusively, a correlation between cutting force behavior and surface roughness was established and confirmed by the three-dimensional topographic maps of the machined surfaces. The RSM was utilized to define the optimal machining parameters.

Optimization of machining parameters for fine turning operations based on the response surface method

Machining of aluminium parts has become particularly important in recent years. Surface roughness measurements are essential in the characterization of the surface integrity of a machined surface. To examine the effect of cutting parameters on surface roughness thoroughly, a huge number of experiments are needed, depending on the number of parameters. By utilizing the method of design of experiments, the number of experiments is reduced, as determined by the effects of the parameters. If linear effects of cutting parameters are considered, then fractional factorial design is sufficient, but to take into consideration the interactions between the factors and the quadratic terms, the response surface method has to be utilized. The machinability of two AlSi alloys with diamond tools is examined using the response surface method. During the experiments the cutting parameters (cutting speed, feed rate, depth of cut) were changed systematically and the surface roughness was measured as an output parameter. The significant factors are determined by statistical analysis, and a mathematical model is developed to describe the relationship between the surface roughness and the cutting parameters. Optimization determines the appropriate manufacturing parameters for the manufacturing process planning. References A. Dregelyi-Kiss, R. Horvath and B. Miko. Design of experiments DOE in investigation of cutting technologies. Scientific Research Reports vol. 3. Krakow University, 2012. H. Aouici, M. A. Yallese, K. Chaoui, T. Mabrouki and J.-F. Rigal. Analysis of surface roughness and cutting force components in hard turning with CBN tool: Prediction model and cutting conditions optimization. Measurement, 45:344–353, 2012. doi:10.1016/j.measurement.2011.11.011 M. Y. Noordin, D. Kurniawan, Y. C. Tang and K. Muniswaran. Feasibility of mild hard turning of stainless steel using coated carbide tool. Int. J. Adv. Manuf. Tech., 60:853–863, 2012. doi:10.1007/s00170-011-3656-0 I. Asilturk and S. Neseli. Multi response optimisation of CNC turning parameters via Taguchi method-based response surface analysis. Measurement, 45:785–794, 2012. doi:10.1016/j.measurement.2011.12.004 Y. K. Hwang and C. M. Lee. Surface roughness and cutting force prediction in MQL and wet turning process of AISI 1045 using design of experiments. J. Mech. Sci. Technol., 24:1669–1677, 2010. doi:10.1007/s12206-010-0522-1 M. Harnicarova, J. Valicek, M. Kusnerova, R. Grznarik, J. Petru and L. Cepova. A new method for the prediction of laser cut surface topography. Meas. Sci. Rev., 12:195–204, 2012. doi:10.2478/v10048-012-0030-9 D. Lazarevic, M. Madic, P. Jankovic and A. Lazarevic. Surface roughness minimization of polyamide pa-6 turning by Taguchi method. J. Prod. Engineer., 15:29–32, 2012. http://www.jpe.ftn.uns.ac.rs/papers/2012/no1/7-Lazarevic.pdf R. Horvath and A. Dregelyi-Kiss. Analysis of surface roughness parameters in aluminium fine turning with diamond tool. Measurement 2013 Conference, Smolenice, Slovakia, 275–278, 2013. http://www.measurement.sk/M2013/ R. Horvath, A. Dregelyi-Kiss and Gy. Matyasi. Application of RSM method for the examination of diamond tools. Acta Polytech. Hung., 11:137–147, 2014. doi:10.12700/APH.11.02.2014.02.8 TiroTool Werkzeugsysteme Gmbh. http://www.tirotool.com/

Cutting force prediction and analytical solution of regenerative chatter stability for helical milling operation

As a new type, highly efficient hole-making technique, helical milling is widely used to generate holes on composites and composite-metal compounds in the aircraft industry. The accurate prediction of cutting forces and chatter stability are essential for achieving a highly efficient and chatter-free helical milling process by cutting condition optimization. On the basis of a quantitative description of cutting zones corresponding to helical milling operation, a novel dynamic cutting force model is proposed for helical milling in this paper, in which the cutting mechanism and the cutting force contribution on both the peripheral and the front cutting edges are taken into consideration simultaneously. An analytical stability prediction method is also proposed to obtain a novel stability lobe diagram represented by the ratio of the axial to the tangential feed per tooth with regard to the spindle speed using a numerical approach to calculate the average directional cutting force coefficients. The proposed method is capable of predicting the stability lobes accurately for helical milling process where different types of cutting mechanism exist and the axial depth of cut is time varying. It is shown that the numerical predictions agree well with the cutting tests. Finally, the effect of cutting conditions on both the cutting forces and stability limits are thoroughly analyzed.

Prediction of dynamic cutting force and regenerative chatter stability in inserted cutters milling

Currently, the modeling of cutting process mainly focuses on two aspects: one is the setup of the universal cutting force model that can be adapted to a broader cutting condition; the other is the setup of the exact cutting force model that can accurately reflect a true cutting process. However, there is little research on the prediction of chatter stablity in milling. Based on the generalized mathematical model of inserted cutters introduced by ENGIN, an improved geometrical, mechanical and dynamic model for the vast variety of inserted cutters widely used in engineering applications is presented, in which the average directional cutting force coefficients are obtained by means of a numerical approach, thus leading to an analytical determination of stability lobes diagram (SLD) on the axial depth of cut. A new kind of SLD on the radial depth of cut is also created to satisfy the special requirement of inserted cutter milling. The corresponding algorithms used for predicting cutting forces, vibrations, dimensional surface finish and stability lobes in inserted cutter milling under different cutting conditions are put forward. Thereafter, a dynamic simulation module of inserted cutter milling is implemented by using hybrid program of Matlab with Visual Basic. Verification tests are conducted on a vertical machine center for Aluminum alloy LC4 by using two different types of inserted cutters, and the effectiveness of the model and the algorithm is verified by the good agreement of simulation result with that of cutting tests under different cutting conditions. The proposed model can predict the cutting process accurately under a variety of cutting conditions, and a high efficient and chatter-free milling operation can be achieved by a cutting condition optimization in industry applications.

Analysis of surface roughness and cutting force components in hard turning with CBN tool: Prediction model and cutting conditions optimization

In this study, the effects of cutting speed, feed rate, workpiece hardness and depth of cut on surface roughness and cutting force components in the hard turning were experimentally investigated. AISI H11 steel was hardened to (40; 45 and 50) HRC, machined using cubic boron nitride (CBN 7020 from Sandvik Company) which is essentially made of 57% CBN and 35% TiCN. Four-factor (cutting speed, feed rate, hardness and depth of cut) and three-level fractional experiment designs completed with a statistical analysis of variance (ANOVA) were performed. Mathematical models for surface roughness and cutting force components were developed using the response surface methodology (RSM). Results show that the cutting force components are influenced principally by the depth of cut and workpiece hardness; on the other hand, both feed rate and workpiece hardness have statistical significance on surface roughness. Finally, the ranges for best cutting conditions are proposed for serial industrial production.

Application of Neural Network on Burr Expert System in Micro-machining

The demands placed by designers on workpiece performance and functionality are increasing rapidly. Important aspects of manufacturing's contribution to the fulfillment of these demands are the conditions at the work piece edges. However, Burrs are often created on the workpiece edges in micro-machining. In many cases, time consuming and expensive deburring processes have to be applied in order to ensure the desired part functionality. Burrs make troubles on production lines in terms of deburring cost, quality of products and cutting tool wear. To prevent problems caused by burrs in micro-machining, prediction and control of burr size is desirable. Experimental studies show that burr formation in micro- milling is a highly complex process depending on a number of parameters such as material properties, tool geometry and cutting parameters. It is very difficult to establish the relationship between burr sizes and cutting conditions. A web-based micro-machining burr expert system for burr sizes prediction and control was developed using ASP.NET platform. Burrs types and sizes prediction and cutting conditions optimization for burr controlling which based on the reasoning method of BP neural networks are realized. Operation results show that the system is reliable. It provides a new technology for burrs modelling and controlling. Index Terms—burr expert system, neural network, micro- machining, burr prediction, edge quality

Application and Analysis of RBF Neural Network for Burr Prediction in Micro-Machining

Micro-milling is widely used in material removal processes in industry. However, burrs are often formed on workpiece edges in milling process. Burr effects the dimensional tolerance and performance of the workpiece seriously and is desirable to be controlled. Burrs prediction technology is useful for cutting conditions optimization to control burrs forming. Due to lots of factors influencing the formation process of burr, it is a difficult task to establish the burr size prediction model by mathematical and mechanical method. RBF neural network was used for burr formation predition. Design of the network, network structure parameters determination and generalization capability of the network were analyzed and discussed. Achieved network has good fitting performance and generalization capability validated by experiments.

Dynamic Simulation and Cutting Conditions Optimization of Tee Slot Milling Based on CutPro Software

. Based on the dynamic simulation module of CutPro, the dynamic cutting forces and chatter limits for tee slot milling were predicated by setting the geometry of a tee slotting cutter. The chatter stability lobes under a given axial depth of cut are obtained by further programming, which is essential for chatter-free tee slot milling. A methodology of cutting conditions optimization for tee slot milling is presented, in which the minimal cutting time is used as the target function and the stability limits are introduced into the constraint conditions to reflect the vibration characteristics of milling operation. This optimization method has been validated by experimental tests.

Dynamic Simulation and Cutting Conditions Optimization of Tee Slot Milling Based on CutPro Software

. Based on the dynamic simulation module of CutPro, the dynamic cutting forces and chatter limits for tee slot milling were predicated by setting the geometry of a tee slotting cutter. The chatter stability lobes under a given axial depth of cut are obtained by further programming, which is essential for chatter-free tee slot milling. A methodology of cutting conditions optimization for tee slot milling is presented, in which the minimal cutting time is used as the target function and the stability limits are introduced into the constraint conditions to reflect the vibration characteristics of milling operation. This optimization method has been validated by experimental tests.

B18 An Approach to Cutting Condition Optimization in End Milling : Its Concept and Analytical Shear Angle Prediction Model(Advanced machining technology)

B18 An Approach to Cutting Condition Optimization in End Milling : Its Concept and Analytical Shear Angle Prediction Model(Advanced machining technology)

309 工具費削減のためのエンドミル工具の標準化手法(OS-5 生産システムとCAD・CAM)

The phrase 'standardization' is indicative of competitiveness in the Japanese manufacturing industry. In manufacturing plants, a wide variety of cutting tools is in use today. In many cases, the cutting tools are stored in disarray. The cutting tool management is far from well-ordered. This paper describes a logical procedure of standardizing the cutting tool specification. The eternal objectives of manufacturing industry are lead time reduction and cost reduction. The accessible as well as effective way of achieving them is the optimization of the manufacturing process. The manufacturing process optimization in metal cutting consists of three basic elements ; cutting tool standardization, CAM utilization, and cutting condition optimization. The standardization of cutting tool specifications is the foundation for improving productivity. Therefore, the cutting tool standardization is inextricably linked with lead time reduction and cost reduction, and should be considered business challenge.

1418 マシニングセンタにおけるエンドミル切削条件の最適化手法(G13-3 生産加工・工作機械(3),G13 生産加工・工作機械)

1418 マシニングセンタにおけるエンドミル切削条件の最適化手法(G13-3 生産加工・工作機械(3),G13 生産加工・工作機械)

Cutting conditions optimization when turning overlays

In this paper are the published results of the systematic study of cutting conditions suitable for selected overlay type machining. With regard to overlay specific properties, the cutting conditions optimization starts usually from long-term tool-life tests. In this way, the determinated tool-life T–cutting speed v relationships are the starting values for the proper cutting conditions optimization, mostly calculated for the criterion of minimum productions costs. The overlay hardness HRC measurement, the study of chips shape and size and the surface roughness measurement were also part of the tests. On the basis of these tests and calculations, it is possible to state that three of five tested cutting materials are suitable for machining of this type of overlay. During the tests, it was proved that it is possible to evalute the overlay machining process with the chips form and surface roughness monitoring.

Feature Based Continuous Cutting Conditions Optimization on the Tool Path in 2 1/2 Axis Milling

Feature Based Continuous Cutting Conditions Optimization on the Tool Path in 2 1/2 Axis Milling