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Machining Optimization

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PRACHI 1956 (RA2111026010111)
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8 views

Machining Optimization

Uploaded by

PRACHI 1956 (RA2111026010111)
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Machining Optimization

• Optimization of machining processes is one of the most widely investigated


problems in machining.
• The objective functions in the machining problems are:
(1) minimization of cost of machining
(2) maximization of production rate
(3) maximization of profit rate
• A weighted combination of these objectives may be taken, or the problem can
be solved as a multi-objective optimization problem.
• In the machining optimization problem, there are constraints on tool life,
surface finish, cutting force, machining power, etc.
• Usually the machining processes are performed in a number of passes
 the last pass is the finishing pass
 other passes are the rough passes
• In a multipass machining process, the cutting speed, feed, and depth of cut in
each pass are the primary variables.
Objective Functions and Constraints
• Consider the multipass turning of a cylindrical work piece of length L, initial
diameter and final diameter .
• The production time per component is given by

Where is the total cutting time for rough machining


is the time required for changing a tool
is the tool life
is the total cutting time for finish machining
is the job loading and unloading time
is the total tool setting time for a job
• The total cutting time for rough machining is obtained as the summation of the
cutting time for m roughing passes.

where and are the cutting speed and feed at the ith roughing pass
is the workpiece diameter at the beginning of that pass
• The cutting speed is defined as the surface speed of the workpiece at the
beginning of the pass.
• The total tool setting time is given as

where is the setting time for each pass.


Tool Life
• The tool life T is a critical parameter for the objective function.
• The tool life is a function of machining parameters, viz. feed (f), cutting velocity (v),
and depth of cut (d) as well as the tool–job combination and the machine tool.
• For a given machine tool and tool–job combination, the tool life can be expressed
as a function of f, v, and d.
• A neural network can be used for online prediction of the tool life
• The cost of machining for a workpiece, , can be expressed as

where is the operating cost per unit time


is the tool change cost for a roughing tool
is the tool change time for a finishing tool.
• If the same tool is used for roughing and finishing passes, then
• If the price of a work piece is fixed as , then the profit rate is
expressed as

• The above equations can be used as the objective functions.


Machining optimization Constraints
The machining optimization problem may be subjected to various
constraints:
1. Constraint on the tool life
2. Constraint on the surface finish
3. Constraints on the machining forces
4. Constraint on the machining power
5. Constraints on vibrations
6. Constraint on dimensional deviation
7. Constraints on geometric relations
Constraint on the tool life

• The tool life should not be too low or too high.


• If the tool life is too low, then it will fail without machining even one piece.
• While machining a workpiece, if the tool is changed in between, it will
affect the surface finish and dimensional accuracy of the workpiece.
• As a thumb rule, the tool life should be at least such that 20 components
can be produced without the need of replacing the tool.
• In other words, the deterioration in tool life should be limited to less than
5% in machining a component.
• Initially, it appears that there is no need to have a constraint on the
maximum permissible tool life.
• However, a close examination of shop floor practice reveals that there is no
advantage in operating at parameters providing too high value of tool life.
• If the tool life is too high, tools may be underutilized.
• Also, if certain types of tools have been specifically procured for a
particular batch production, often it may not be advantageous to
preserve the tools once the entire batch has been produced.
• In that case also, too high a tool life will mean underutilization of
tools.
• However, in most cases, the constraint on tool life may turn out to be
an inactive constraint.
Constraint on the surface finish

• Mostly, a constraint on the upper limit of surface roughness is


prescribed.
• However, the possibility of having a constraint on the lower limit of
the surface roughness cannot be ignored.
• Surface roughness affects the heat transfer characteristics and a
rough surface is beneficial, for example, in order to have greater heat
transfer in a pool boiling process.
• Similarly, a specific tribological characteristic may be obtained by
controlling the surface roughness.
• For the given process parameters, the surface roughness may be
predicted by a trained neural network.
Constraints on the machining forces
• The neural network can be used for the modelling of cutting forces in
a machining process.
• These forces should be less than the prescribed forces to avoid tool
breakage and excessive deflections of the job and the tool.
Constraint on the machining power
• The machining power is obtained by dividing the product of the main
cutting force and cutting speed by the efficiency of the machine tool.
• The machining power constraint requires that the machining power
be less than the prescribed power.
Constraints on vibrations
• The vibrations during a machining process should be low as they affect
the accuracy and precision of the job.
Constraint on dimensional deviation
• The dimensional deviation of the workpiece should be kept within the
prescribed limit.
• If a model for predicting the dimensional deviation in machining is
available, it can be used in this constraint.
• Otherwise the constraints on machining forces will indirectly impose
the constraint on dimensional deviation.
Constraints on geometric relations
• It is obvious that the number of passes m in a machining operation is an integer
quantity.
• The following geometric relation has to be satisfied for the multi-pass turning
process:

where Df is the diameter of the finished job


dRi is the depth of cut of the ith roughing pass
dF is the depth of cut of the finish pass.
• Apart from these constraints, there are variable bounds on the cutting speed, feed
and depth of cut.

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