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Alternative optimisation strategies and CAM software for multipass rough turning operations

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Abstract

The development of constrained optimisation analyses and strategies for selecting optimum cutting conditions in multipass rough turning operations based on minimum time per component criterion is outlined and discussed. It is shown that a combination of theoretical economic trends of single and multipass turning as well as numerical search methods are needed to arrive at the optimum solution. Numerical case studies supported the developed solution strategies and demonstrated the economic superiority of multipass strategies over single pass. Alternative approximate multipass optimisation strategies involving equal depth of cut per pass, single pass optimisation strategies and limited search techniques have also been developed and compared with the “rigorous” optimisation strategies. The approximate strategies have been shown to be useful, preferably for “on-line” applications such as “canned cycles” on CNC machine controllers, but recourse to the “rigorous” multipass strategies should be regarded as the reference for use in assessing alternative approximate strategies or for CAM support usage.

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Abbreviations

d i :

depth of cut for theith pass

d opt :

optimum depth of cut

d T :

total depth of cut to be removed

D i :

workpiece diameter before theith pass

D o,D m :

initial and final workpiece diameter (afterm passes)

f i :

feed for theith pass

f max,f min :

machine tool maximum and minimum feed

f opt :

optimum cutting feed

f sj, Vsj :

available feed and speed steps in a conventional machine tool

f sgl, frec :

optimum and handbook recommended single pass cutting feeds

F pmax :

maximum permissible cutting force

L :

workpiece length of cut

m :

continuous number of passes

m H :

next higher integer number of passes from a givenm

m HW :

upper limit to the optimum integer number of passesm opt

m L :

next lower integer number of passes from a givenm

m LW :

lower limit to the optimum integer number of passesm opt

m o :

optimum (continuous) number of passes

m opt :

optimum integer number of passes

N a :

machine tool critical rotational speed whenP a=P max

N max,N min :

machine tool maximum and minimum rotational speed

n,n 1,n 2,K :

speed, feed and depth of cut exponents and constant in the extended Taylor's tool-life equation

P a,P max :

machine tool low speed and maximum power constraints

T i :

tool-life using the cutting conditions for theith pass

T L :

loading and unloading time per component

T R :

tool replacement time

T s :

tool resetting time per pass

T T :

production time per component

T TDi :

multi-passT T equation with workpiece diameter effect

T TDm, TTDo :

multi-passT T equations with constant diameterD m andD o, respectively

T Topt :

overall optimum time per component

T Tsgl :

optimum time per component for single pass turning

T T2re c :

handbook recommended time per component

V i :

cutting speed for theith pass

V max,V min :

machine tool maximum and minimum cutting speed

V sgl,V rec :

optimum and handbook recommended single pass cutting speeds

V opt :

optimum cutting speed

a, E, W :

empirical constants in theP a/F pmax/P max equations

α, β, γ:

feed, depth and speed exponents inF pmax andP max equations

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Kee, P.K. Alternative optimisation strategies and CAM software for multipass rough turning operations. Int J Adv Manuf Technol 10, 287–298 (1995). https://doi.org/10.1007/BF01178982

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