4_cutting.ppt-IELM.pptVIP

Process parameters optimization: feed Rough cutting: MRR ? cutting speed, V MRR ? feed, f ? cannot increase V and f arbitrarily ↑ V ? ↑ MRR; surface finish ≠ f(V); energy per unit volume MRR ≠ f(V) Tool temperature ? V, f; Friction wear ? V; Friction wear ≠ f For a given increase in MRR: ↑ V ? lower tool life than ↑ f Optimum feed: maximum allowed for tool [given machine power, tool strength] Process parameters optimization: Speed ? provided upper limits, but not optimum Need a relation between tool life and cutting speed (other parameters being constant) Model objective: Given optimum feed, what is the optimum cutting speed Taylor’s model (empirically based): V tn = constant Process parameters optimization: Speed One batch of large number, Nb, of identical parts Replace tool by a new one whenever it is worn Total non-productive time = Nbtl tl = time to (load the stock + position the tool + unload the part) Nb be the total number of parts in the batch. Total machining time = Nbtm tm = time to machine the part Total tool change time = Nttc tc = time to replace the worn tool with a new one Nt = total number tools used to machine the entire batch. Cost of each tool = Ct, Cost per unit time for machine and operator = M. Average cost per item: Process parameters optimization: Speed Average cost per item: Let: total length of the tool path = L t = tool life ? Nt = (Nb tm)/t ? Nt / Nb = tm / t Taylor’s model Vtn = C’ ? t = C’ 1/n / V1/n = C/V1/n Process parameters optimization: Speed Average cost per item: Process parameters optimization: Speed Optimum speed (to minimize costs) Optimum speed (to minimize time) Average time to produce part: Process parameters optimization: Speed Optimum speed (to minimize costs) Optimum speed (to minimize time) Average time to produce part: load/unload time machining time tool change time Substitute, differentiate, solve for V* Process Planning The process plan specifies: operations tools, path