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Application to Machining
1
Selection of Cutting Conditions
2
Optimization Criteria
Commonly employed optimization criteria (objectives)
are:
Max. production rate or min. production time: aims to
maximize number of parts produced in a unit time interval or
minimizes the time per unit part. Neglects cost and/or profit.
3
Decision Variables
Feed (f )
4
Definitions (1)
Unit production time, t (min/pt): time to manufacture
a unit of the product.
t = tp + tm + tr
Where,
tp = setup time (min/pt); includes time needed to load/unload parts
into machine, tool setup time, etc.
tm = machining time (min/pt)
tr = total tool replacement time (min/pt) = tc(tm/T)
tc = time needed to replace a worn cutting edge with a new one
(min/edge)
T = tool life (min)
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ME 4210: Manufacturing Processes & Engineering
Instructor: Ramesh Singh; Notes by: Prof. S.N. Melkote
Unconstrained Optimization (1)
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Unconstrained Optimization (2)
In general,
tm = /V
n
VT = C
Where T = tool life (min), C = 1 min. tool life
cutting speed, n = function of tool-workpiece
material.
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Unconstrained Optimization (4)
Expressing t, u in terms of V, we get:
1nn 1/ n
t = t p + ( V ) + tc V C
1nn 1/ n
u = kot p + ( ko + km )( V ) + ( kt + kotc ) V C
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Unconstrained Optimization (5)
Optimal cutting speed (and corresponding
tool life) can be obtained by standard calculus
as:
Min. time or max. production rate criterion:
n
1 n
Vopt = C tc
n
1 n
Topt = tc
n
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Unconstrained Optimization (6)
Min. cost criterion:
n
( ko + k m )
Vopt =C
1 n (k + k t )
n t o c
1 n ( k t + k o tc )
Topt =
n ( ko + k m )
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Unconstrained Optimization Example
(1)
Given:
Taylor tool life equation VT0.23 = 430, V (m/min)
Machining (turning) parameters
Depth of cut, d = 1.00 mm
Feed, f = 0.2 mm/rev
Workpiece geometry
Workpiece diameter, D = 50 mm
Workpiece length, L = 200 mm
Time parameters
Setup time, tp = 0.75 min/pt
Tool replacement time, tc = 1.5 min/edge
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Unconstrained Optimization Example
(2)
Given:
Cost parameters
Machine utilization rate, ko = 0.50 $/min
Machining overhead, km = 0.05 $/min
Tool cost, kt = 2.50 $/edge
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Unconstrained Optimization Example
(3)
Min. time or max. production rate cutting
speed and tool life:
n 0.23
1 n 1 0.23
Vopt = C tc = 430 1.5 = 296 m/min
n 0.23
1 n 1 0.23
Topt = tc = 1.5 = 5 min
n 0.23
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Unconstrained Optimization Example
(4)
Min. cost cutting speed and tool life:
n 0.23
( ko + k m ) ( 0.5 + 0.05)
Vopt =C = 430 = 216 m/min
1 n (k + k t ) 1 0.23 ( 2.5 + 0.5 1.5)
n t o c
0.23
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Summary
Unconstrained optimization
Optimum cutting speeds
Production time and cost criteria
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