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Analysis of Tool Utilization from Material Removal Rate Perspective
University West, Department of Engineering Science, Research Enviroment Production Technology West. (PTW)ORCID iD: 0000-0002-2146-7916
University West, Department of Engineering Science, Division of Production Engineering. (PTW)
University West, Department of Engineering Science, Division of Manufacturing Processes. (PTW)ORCID iD: 0000-0002-3436-3163
GKN Aerospace Engine Systems AB, Trollhättan, Sweden.
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.

Place, publisher, year, edition, pages
2015. Vol. 29, p. 109-113
Keywords [en]
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: urn:nbn:se:hv:diva-7614DOI: 10.1016/j.procir.2015.02.183Scopus ID: 2-s2.0-84939630891OAI: oai:DiVA.org:hv-7614DiVA, id: diva2:815922
Conference
The 22nd CIRP Conference on Life Cycle Engineering
Available from: 2015-06-02 Created: 2015-05-30 Last updated: 2018-04-06Bibliographically approved
In thesis
1. Analysis and direct optimization of cutting tool utilization in CAM
Open this publication in new window or tab >>Analysis and direct optimization of cutting tool utilization in CAM
2015 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

The search for increased productivity and cost reduction in machining can be interpreted as the desire to increase the material removal rate, MRR, and maximize the cutting tool utilization. The CNC process is complex and involves numerous limitations and parameters, ranging from tolerances to machinability. A well-managed preparation process creates the foundations for achieving a reduction in manufacturing errors and machining time. Along the preparation process of the NC-program, two different studies have been conducted and are presented in this thesis. One study examined the CAM programming preparation process from the Lean perspective. The other study includes an evaluation of how the cutting tools are used in terms of MRR and tool utilization.

The material removal rate is defined as the product of three variables, namely the cutting speed, the feed and the depth of cut, which all constitute the cutting data. Tool life is the amount of time that a cutting tool can be used and is mainly dependent on the same variables. Two different combinations of cutting data might provide the same MRR, however the tool life will be different. Thereby the difficulty is to select the cutting data to maximize both MRR and cutting tool utilization. A model for the analysis and efficient selection of cutting data for maximal MRR and maximal tool utilization has been developed and is presented. The presented model shortens the time dedicated to the optimized cutting data selection and the needed iterations along the program development.

Place, publisher, year, edition, pages
Trollhättan: University West, 2015. p. 82
Series
Licentiate Thesis: University West ; 7
Keywords
CAM programming; Material Removal Rate; Tool life; Tool wear; Tool utilization; Cutting data; Lean; Optimization; CIM; Integration IT tools; Manufacturing
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
ENGINEERING, Manufacturing and materials engineering; Production Technology
Identifiers
urn:nbn:se:hv:diva-8672 (URN)978-91-87531-14-9 (ISBN)978-91-87531-13-2 (ISBN)
Presentation
2015-11-27, C-118, University West, Trollhättan, 10:00 (English)
Opponent
Supervisors
Available from: 2015-11-18 Created: 2015-11-17 Last updated: 2016-11-13Bibliographically approved
2. On cutting tool resource management
Open this publication in new window or tab >>On cutting tool resource management
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 ; 16
Keywords
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:nbn:se:hv:diva-12240 (URN)978-91-87531-82-8 (ISBN)978-91-87531-81-1 (ISBN)
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: 2018-10-26Bibliographically approved

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Bonilla Hernández, Ana EstherRepo, Jari

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