Optimisation of machining parameters for milling operations using a scatter search approach

ORIGINAL ARTICLE
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Abstract

This paper describes the application of a newly developed metaheuristic, the scatter search, for optimising the machining parameters of milling operations. An objective function based on maximum profit is used while considering the practical constraints, such as allowable speed and feed, maximum machine power, surface finish requirement and maximum cutting speed permitted by the rigidity of the machine tool. An example is taken from the literature for comparing the results of the proposed method with other heuristics and handbook recommendations.

Keywords

Milling Optimisation Scatter search Multi-tool operations 

Nomenclature

A

chip cross-sectional area (mm2)

a, arad

axial depth of cut, radial depth of cut (mm)

C

constant in cutting speed equation

ca

clearance angle of the tool (°)

Ci (i=1–8)

coefficients carrying constant values

cl, co

labour cost, overhead cost ($/min)

cm, cmat, ct

machining cost, cost of raw material per part, cost of cutting tool($)

Cu

unit cost ($)

d

cutter diameter (mm)

e

machine tool efficiency factor

F

feed rate (mm/min)

f

feed rate (mm/tooth)

Fc, Fc(per)

cutting force, permitted cutting force (N)

FF, FR, FT

feed, radial and tangential forces resulting from all active cutting teeth (N)

G, g

slenderness ratio, exponent of slenderness ratio

K

distance to be travelled by the tool to perform the operation (mm)

Ki (i=1–3)

coefficients carrying constant values

Kp

power constraint depending on the work piece material

la

lead (corner) angle of the tool

m

number of machining operations required

N

spindle speed (rev/min)

n

tool life exponent

P, Pm

required power for an operation, maximum power (KW)

Pr

total profit rate ($/min)

Q

contact proportion of cutting edge with work piece per revolution

R

sale price of the product excluding material, set-up and tool changing costs ($)

Ra, Ra(at)

arithmetic value of surface finish, attainable surface finish (μm)

Sp

sale price of the product ($)

T, Tu

tool life (min), unit time (min)

tm, ts, ttc

machining time, set-up time, tool changing time (min)

V, Vhb, Vopt

cutting speed, speed recommended by handbook, optimum speed (m/min)

w

exponent of chip cross-sectional area

W

tool wear factor

z

number of cutting teeth on the tool

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References

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Copyright information

© Springer-Verlag London Limited 2006

Authors and Affiliations

  1. 1.Department of Mechanical Engineering, College of EngineeringJ.N.T. UniversityKakinadaIndia

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