Adaptive Tool Replacement Policies in Machining Economics

1996 ◽  
Vol 118 (4) ◽  
pp. 658-663 ◽  
Author(s):  
E. Iakovou ◽  
C. M. Ip ◽  
C. Koulamas
Keyword(s):  
Tool Life ◽  
Cutting Speed ◽  
Control Policy ◽  
Replacement Policy ◽  
Machining Process ◽  
Time To Failure ◽  
Preventive Replacement ◽  
Machining Economics ◽  
Production Run ◽  
Tool Replacement

Optimization of the economics of machining comprises the determination of the optimal cutting speed and tool replacement policy. A necessary input to the above approach is knowledge of the parameters of the tool life equation which links tool life to cutting speed. In reality, these parameters are not known and should be estimated based on actual machining data. This paper addresses the above optimization problem in the framework of an adaptive control policy. Replacement times in one production run are used to estimate the mean-time-to-failure of a tool, which is in turn used in a regression model to update estimators of the tool life parameters. Using the newly updated estimates a new cutting speed and preventive replacement policy are then determined for the next production run. The end result is an easily implementable decision making tool which can aid in the continuous improvement of the machining process.

Model for Economic Optimization of the Tool Life and the Cutting Speed at Drilling of the Steel X5CrNiMo17-12-2

2015 ◽  
Vol 809-810 ◽  
pp. 63-68 ◽  
Author(s):  
Marius Iacob ◽  
Ovidiu Blăjină ◽  
Aurelian Vlase
Keyword(s):  
Tool Life ◽  
Cutting Tool ◽  
Programming Model ◽  
Cutting Speed ◽  
Machining Process ◽  
Economic Optimization ◽  
Manufacturing Activity ◽  
Nonlinear Programming Model ◽  
The Cost ◽  
Accuracy Of Prediction

In the specialized literature the cost of the machining process has been analyzed using a number of approaches and varying degrees of simplification to determine the optimum tool life and the tool speed. The accuracy of prediction is dependent on the degree of sophistication of the model. The purpose of this paper is the optimization of the cutting tool life and the cutting speed at the drilling of the stainless steels in terms of the minimum machining cost. A more comprehensive nonlinear programming model to minimize the total cost at the drilling of a stainless steel is developed in this paper. The optimum tool life and the associated tool speed are obtained by solving this model. The results can be taken into consideration in the educational studies and in the theoretical technical research. They can be implemented in the manufacturing activity.

scholarly journals The effect of changes in depth of cut and cutting speed of CNC toolpaths on turning process performance

2018 ◽  
Vol 38 (1) ◽  
pp. 40-44
Author(s):  
Krzysztof Jarosz ◽  
Piotr Niesłony ◽  
Piotr Löschner
Keyword(s):  
Cutting Force ◽  
Tool Life ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Process Performance ◽  
Turning Process ◽  
Machining Time ◽  
Toolpath Optimization ◽  
The Impact

Abstract In this article, a novel approach to computer optimization of CNC toolpaths by adjustment of cutting speed vcand depth of cut apis presented. Available software works by the principle of adjusting feed rate on the basis of calculations and numerical simulation of the machining process. The authors wish to expand upon this approach by proposing toolpath optimization by altering two other basic process parameters. Intricacies and problems related totheadjustment of apand vcwere explained in the introductory part. Simulation of different variant of the same turning process with different parameter values were conducted to evaluate the effect of changes in depth of cut and cutting speed on process performance. Obtained results were investigated on the account of cutting force and tool life. The authors have found that depth of cut substantially affects cutting force, while the effect of cutting speed on it is minimal. An increase in both depth of cut and cutting speed affects tool life negatively, although the impact of cutting speed is much more severe. An increase in depth of cut allows for a more significant reduction of machining time, while affecting tool life less negatively. On the other hand, the adjustment of cutting speed helpsto reduce machining time without increasing cutting force component values and spindle load.

Improved Model to Determine the Tool Life and the Cutting Speed for Minimum Cost at Drilling the Steel 10TiMoNiCr175

2013 ◽  
Vol 837 ◽  
pp. 234-238
Author(s):  
Aurelian Vlase ◽  
Ovidiu Blăjină ◽  
Vlad Darie
Keyword(s):  
Tool Life ◽  
Programming Model ◽  
Cutting Speed ◽  
Minimum Cost ◽  
Machining Process ◽  
Manufacturing Activity ◽  
Nonlinear Programming Model ◽  
Improved Model ◽  
The Cost ◽  
Accuracy Of Prediction

In the specialized literature the cost of the machining process has been analyzed using a number of approaches and varying degrees of simplification to determine the optimum tool life and the tool speed. The accuracy of prediction is dependent on the degree of sophistication of the model. The purpose of this paper is the optimization of the cutting tool life and the cutting speed at the drilling of the stainless steels in terms of the minimum machining cost. A more comprehensive nonlinear programming model to minimize the total cost at the drilling of a stainless steel is developed in this paper. The optimum tool life and the associated tool speed are obtained by solving this model. The results can be taken into consideration in the educational studies and in the theoretical technical research. They can be implemented in the manufacturing activity.

Model for Economic Optimization of the Tool Life and the Cutting Speed at Drilling of the Steel 2NiCr185

2015 ◽  
Vol 760 ◽  
pp. 439-444 ◽  
Author(s):  
Ovidiu Blăjină ◽  
Aurelian Vlase ◽  
Marius Iacob
Keyword(s):  
Tool Life ◽  
Cutting Tool ◽  
Programming Model ◽  
Cutting Speed ◽  
Machining Process ◽  
Economic Optimization ◽  
Manufacturing Activity ◽  
Nonlinear Programming Model ◽  
The Cost ◽  
Accuracy Of Prediction

In the specialized literature the cost of the machining process has been analyzed using a number of approaches and varying degrees of simplification to determine the optimum tool life and the tool speed. The accuracy of prediction is dependent on the degree of sophistication of the model. The purpose of this paper is the optimization of the cutting tool life and the cutting speed at the drilling of the stainless steels in terms of the minimum machining cost. A more comprehensive nonlinear programming model to minimize the total cost at the drilling of a stainless steel is developed in this paper. The optimum tool life and the associated tool speed are obtained by solving this model. The results can be taken into consideration in the educational studies and in the theoretical technical research. They can be implemented in the manufacturing activity.

A Three-Dimensional, Tool-Life Equation—Machining Economics

1959 ◽  
Vol 81 (3) ◽  
pp. 239-249 ◽  
Author(s):  
Bertil N. Colding
Keyword(s):  
Tool Life ◽  
Three Dimensional ◽  
Cutting Speed ◽  
Minimum Cost ◽  
Optimum Combination ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Edge Angle ◽  
Machining Economics ◽  
General Tool

In Part 1 of this paper, two tool-life equations are derived, one limited equation and one general tool-life equation, between the variables cutting speed, chip equivalent, and tool life. The chip equivalent, introduced by Woxén, is a well-defined function of feed, depth of cut, nose radius, and side-cutting-edge angle. The limited equation takes into account the variation of Taylor’s exponent n with the value of the chip equivalent, but the equation is only valid within certain limits of cutting speed and chip equivalent. A general equation is then derived on the basis of the limited equation. In Part 2 an expression called the productivity is derived. This relationship is valid for either maximum production or minimum cost and, combined with the general, hyperbolic, tool-life equation, it is used to investigate the optimum combination of tool-life, cutting speed, and chip equivalent.

Empirical Expression of Tool Wear When Face Milling 416 SS

2009 ◽  
Author(s):  
Patricia Mun˜oz de Escalona ◽  
Paul G. Maropoulos
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
Machining Process ◽  
Depth Of Cut ◽  
Milling Operation ◽  
Increase Tool Life ◽  
The Cost

During a machining process, cutting parameters must be taken into account, since depending on them the cutting edge starts to wear out to the point that tool can fail and needs to be change, which increases the cost and time of production. Since wear is a negative phenomenon on the cutting tool, due to the fact that tool life is reduced, it is important to optimize the cutting variables to be used during the machining process, in order to increase tool life. This research is focused on the influence of cutting parameters such as cutting speed, feed per tooth and axial depth of cut on tool wear during a face milling operation. The Taguchi method is applied in this study, since it uses a special design of orthogonal array to study the entire parameters space, with only few numbers of experiments. Also a relationship between tool wear and the cutting parameters is presented. For the studies, a martensitic 416 stainless steel was selected, due to the importance of this material in the machining of valve parts and pump shafts.

scholarly journals Optimization of CNC End Milling Process Parameters of Low-Carbon Mold Steel Using Response Surface Methodology and Grey Relational Analysis

2021 ◽  
Vol 2021 ◽  
pp. 1-11
Author(s):  
R. Suresh Kumar ◽  
S. Senthil Kumar ◽  
K. Murugan ◽  
B. Guruprasad ◽  
Sreekanth Manavalla ◽  
...  
Keyword(s):  
Regression Analysis ◽  
Tool Life ◽  
End Milling ◽  
Cutting Speed ◽  
Optimization Techniques ◽  
Machining Process ◽  
Depth Of Cut ◽  
Low Carbon ◽  
Box Behnken Design ◽  
Cnc End Milling

The manufacturing sectors are consistently striving to figure out ways to minimize the consumption of natural resources through rational utilization. This is achieved by a proper understanding of every minute influence of parameters on the entire process. Understanding the influencing parameters in determining the machining process efficacy is inevitable. Technological advancement has drastically improved the machining process through various means by providing better quality products with minimum machining cost and energy consumption. Specifically, the machining factors such as cutting speed, spindle speed, depth of cut, rate of feed, and coolant flow rate are found to be the governing factors in determining the economy of the machining process. This study is focused on improving the machining economy by enhancing the surface integrity and tool life with minimum resources. The study is carried out on low-carbon mold steel (UNS T51620) using Box–Behnken design and grey regression analysis. The optimized multiobjective solution for surface roughness (Ra), material removal rate (MRR), and power consumed (Pc) and tool life is determined and validated through the confirmatory run. The optimized set of parameters in Box–Behnken design and grey regression analysis with that of confirmatory runs shows a 10% deviation that proves the reliability of the optimization techniques employed.

Performance Comparison between Dry and Nitrogen Gas Cooling when Turning Hardened Tool Steel with Coated Carbide

2015 ◽  
Vol 735 ◽  
pp. 65-69
Author(s):  
Amad Elddein Issa Elshwain ◽  
Mohamed Handawi ◽  
Norizah Redzuan ◽  
M.Y. Noordin ◽  
Denni Kurniawan
Keyword(s):  
Tool Life ◽  
Hard Turning ◽  
Removal Rate ◽  
Cutting Speed ◽  
Production Costs ◽  
Machining Process ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Nitrogen Gas ◽  
Coated Carbide

Dry machining has been successfully used in several machining applications with different cutting tools and workpiece materials due to its environmental friendliness. Dry hard turning has become an alternative machining process to grinding due to its ability to increase material removal rate, reduce production costs, and enhance of material properties. However, hard turning has several issues such as high temperatures at the tool-chip and tool-workpiece interfaces which are affecting negatively on the surface integrity of the machined parts. Using conventional cutting fluids can improve machining performance by reducing the temperature in the cutting area. However, conventional cutting fluids have some issues such as pollution, hazard on operator, high cost, and corrosion for machine tool and workpiece. All these issues related to applications of conventional cutting fluids have encouraged the researchers to look up for another alternative cooling technique in machining operation. Cooling gas has been explored as one of the alternative cooling techniques. The present paper studies the effect of applying nitrogen gas on surface roughness and tool life under different cutting parameters (cutting speed of 100, 135, and 170 m/min, feed of 0.16, 0.2, and 0.24 mm/rev, with constant depth of cut of 0.2 mm) for hard turning of stainless steel (hardness of 48 HRC) using coated carbide tools. Results showed that better surface finish and longer tool life were achieved by using nitrogen gas coolant condition compared to dry cutting.

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