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On cutting tool resource management
University West, Department of Engineering Science, Research Enviroment Production Technology West. (PTW)ORCID iD: 0000-0002-2146-7916
2018 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

The search for increased productivity and cost reduction in machining can be interpreted as desire to increase the Material Removal Rate, , and maximize the cutting tool utilization. The CNC process is complex and involves numerous constraints and parameters; ranging from tolerances to machinability. A well-managed preparation process creates the foundation for achieving a reduction in manufacturing errors and machining time. Along the preparation process of the NC-program, two different studies have been performed and are presented in this thesis. One study examined the CAM programming process from the Lean perspective. The other study includes an evaluation of how the cutting tools are used in terms of and tool utilization. Two distinct combinations of cutting data might provide the same . However, the tool life and machining cost can be different. Therefore, selection of appropriate cutting parameters that best meet all these objectives is challenging. An algorithm for analysis and efficient selection of cutting data for maximal , maximal tool utilization and minimal machining cost has been developed and is presented in this work. The presented algorithm shortens the time dedicated to the optimized cutting data selection and the needed iterations along the program development. Furthermore, the objectives that need to be considered during the estimation of the manufacturing processes sustainability have been identified. In addition, this thesis also includes a theoretical study to estimate energy use, CO2-footprint and water consumption during the manufacture of a workpiece, which can be invaluable for companies in their search for sustainability of their manufacturing processes.

Place, publisher, year, edition, pages
Trollhättan: University West , 2018. , p. 108
Series
PhD Thesis: University West
Keywords [en]
CAM programming; Cutting data; Lean; Manufacturing; Material Removal Rate; Optimization; Tool life; Tool utilization; Tool wear; Sustainability
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology; ENGINEERING, Manufacturing and materials engineering
Identifiers
URN: urn:nbn:se:hv:diva-12240ISBN: 978-91-87531-82-8 (print)ISBN: 978-91-87531-81-1 (electronic)OAI: oai:DiVA.org:hv-12240DiVA, id: diva2:1195696
Public defence
2018-05-08, F104, University West, Trollhättan, 10:15 (English)
Opponent
Supervisors
Available from: 2018-04-12 Created: 2018-04-06 Last updated: 2018-04-11Bibliographically approved
List of papers
1. Analysis of Tool Utilization from Material Removal Rate Perspective
Open this publication in new window or tab >>Analysis of Tool Utilization from Material Removal Rate Perspective
2015 (English)In: Procedia CIRP, ISSN 2212-8271, E-ISSN 2212-8271, Vol. 29, p. 109-113Article in journal (Refereed) Published
Abstract [en]

An end of life strategy algorithm has been used to study a CNC program to evaluate how the cutting inserts are used in terms of their full utilization. Utilized tool life (UTL) and remaining tool life (RTL) were used to evaluate if the insert has been used to its limits of expected tool life, or contributing to an accumulated tool waste. It is demonstrated that possible means to improvement exists to increase the material removal rate (MRR), thereby using the insert until its remaining tool life is as close to zero as possible. It was frequently found that inserts were used well below their maximum performance with respect to cutting velocity.

Keywords
Tool life, tool utilization, material removal rate (MRR)
National Category
Manufacturing, Surface and Joining Technology Computer Systems
Research subject
ENGINEERING, Manufacturing and materials engineering; Production Technology
Identifiers
urn:nbn:se:hv:diva-7614 (URN)10.1016/j.procir.2015.02.183 (DOI)2-s2.0-84939630891 (Scopus ID)
Conference
The 22nd CIRP Conference on Life Cycle Engineering
Available from: 2015-06-02 Created: 2015-05-30 Last updated: 2018-04-06Bibliographically approved
2. Integrated optimization model for cutting data selection based on maximal MRR and tool utilization in continuous machining operations
Open this publication in new window or tab >>Integrated optimization model for cutting data selection based on maximal MRR and tool utilization in continuous machining operations
2016 (English)In: CIRP - Journal of Manufacturing Science and Technology, ISSN 1755-5817, E-ISSN 1878-0016, Vol. 13, p. 46-50Article in journal (Refereed) Published
Abstract [en]

The search for increased productivity can be interpreted as the increase of material removal rate (MRR). Namely, increase of feed, depth of cut and/or cutting speed. The increase of any of these three variables, will increase the tool wear rate; therefore decreasing its tool life according to the same tool life criteria. This paper proposes an integrated model for efficient selection of cutting data for maximal MRR and maximal tool utilization. The results show that, it is possible to obtain a limited range of cutting parameters from where the CAM Programmer can select the cutting data assuring both objectives.

Keywords
Materials removal rate (MRR), tool life, tool wear, cutting data, optimization
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
urn:nbn:se:hv:diva-8674 (URN)10.1016/j.cirpj.2016.02.002 (DOI)000376092800005 ()2-s2.0-84960153710 (Scopus ID)
Note

Ingår i licentiatuppsats. Available online 12 March 2016

Available from: 2015-11-17 Created: 2015-11-17 Last updated: 2018-04-06Bibliographically approved
3. Energy and Cost Estimation of a Feature-based Machining Operation on HRSA
Open this publication in new window or tab >>Energy and Cost Estimation of a Feature-based Machining Operation on HRSA
2017 (English)In: Procedia CIRP, ISSN 2212-8271, E-ISSN 2212-8271, Vol. 61, no Supplement C, p. 511-516Article in journal (Refereed) Published
Abstract [en]

Forward-looking manufacturing companies aim for sustainable production with low environmental footprint. This is true also for aerospace engine-makers, although their environmental impact mostly occurs during the use-phase of their products. Materials, such as Nickel alloys, are used for special applications where other materials will not withstand tough working conditions in terms of pressure and temperature. Heat Resistant Super Alloys are, however, considered difficult to machine and cutting tools will wear off rapidly. In this paper, a simple way to estimate the energy required, the cost and environmental footprint to produce a work piece using standard engineering software is presented. The results show that for a hypothetical 3 tonne work piece, Inconel 718 will be considerably cheaper and require less water but will require more energy, and has considerably larger CO2 footprint than Waspaloy.

Keywords
Energy use, sustainable consumption and production, production cost, environmental footprint, HRSA, feature based machining
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Manufacturing and materials engineering; Production Technology
Identifiers
urn:nbn:se:hv:diva-11573 (URN)10.1016/j.procir.2016.11.141 (DOI)2-s2.0-85020019067 (Scopus ID)
Note

The 24th CIRP Conference on Life Cycle Engineering

Available from: 2017-09-19 Created: 2017-09-19 Last updated: 2018-05-11Bibliographically approved

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Bonilla Hernández, Ana Esther

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