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Analysis and direct optimization of cutting tool utilization in CAM
University West, Department of Engineering Science, Research Enviroment Production Technology West. (PTW)ORCID iD: 0000-0002-2146-7916
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. , 82 p.
Series
Licentiate Thesis: University West, 7
Keyword [en]
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: urn:nbn:se:hv:diva-8672ISBN: 978-91-87531-14-9 (print)ISBN: 978-91-87531-13-2 (print)OAI: oai:DiVA.org:hv-8672DiVA: diva2:871936
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
List of papers
1. 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, 46-50 p.Article 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.

Keyword
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: 2017-01-03Bibliographically approved
2. Streamlining the CAM programming process by Lean Principles within the aerospace industry
Open this publication in new window or tab >>Streamlining the CAM programming process by Lean Principles within the aerospace industry
(English)Manuscript (preprint) (Other academic)
Keyword
CAM programming, Lean Principles, Integration IT tool, CIM, Green manufacturing
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
urn:nbn:se:hv:diva-8673 (URN)
Note

Ingår i lic uppsats

Available from: 2015-11-17 Created: 2015-11-17 Last updated: 2017-02-15Bibliographically approved
3. 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, 109-113 p.Article 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.

Keyword
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: 2016-02-09Bibliographically approved

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Bonilla Hernández, Ana Esther
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