Methods and Models for Cutting Data Optimization

• Traditional optimization of cutting processes refers to minimizing cost or minimizing time (minimumcost or maximum production rate). These criteria apply to the cutting speed via well-known equationsfor economic tool life and tool life for maximum production rate. Quite often speed is focused firstwhen after some suitable feed value is chosen. This is a poor strategy for several reasons.This thesis analyses and suggests suitable strategies, methods, algorithms and models for cuttingdata optimization with general guidelines as well as specific recommendations for some exemplifiedsituations. Effective procedures designed to avoid sub-optimizations and alternative models forminimizing the process costs, maximizing the production rate or minimizing the tool cost whileconsidering a desired cycle time (corresponding to actual demand of the produced part) are centralsubjects for the discussions.In a second phase, tool wear calibration allows for tool replacement coordination to minimizerelated costs, since planned occasions eliminates slack due to operator unattendance, and coordinatedtool replacements minimizes total replacement time.The procedures, methods and models for cutting data optimization discussed have also proven tomake significant cost reductions in several cases even when the process engineers involved in thesestudies generally have long experience and said to have optimized their processes continuously foryears.Although, the models presented in this thesis mainly refer to turning operations, these strategies areapplicable for turning, milling and holemaking processes and especially applicable for medium tolarge lot sizes in multi tool operations, cell balancing, transfer line balancing, etc.

Ämnesord

TEKNIK OCH TEKNOLOGIER  -- Materialteknik (hsv//swe)

ENGINEERING AND TECHNOLOGY  -- Materials Engineering (hsv//eng)

Nyckelord

Tool Life

Cutting Forces

Tool Replacement Coordination

Process Cost

Tooling Cost

Cutting Data Optimization

Surface Finish

Cycle Time Balancing

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