Processing efficiency optimization is often conducted in production environments. For turning, however, the introduction of noncircular cross-section workpieces generates new complexity. This paper presents the kinematic analysis and efficiency optimization of turning a noncircular cross-section workpiece on the basis of ISO 10208:1991 male rope thread machining, characterized by a smooth contour. This thread can be machined, for example, with standard thread turning or using X-axis motions characteristic of noncircular objects, i.e., rope threading. In that case, selecting the proper method and machining parameter values for efficiency can be more challenging than in circular cross-section workpiece turning. The latter method avoids many tool passes but requires highly dynamic movements of the machine in the X-axis. In addition to these two methods, a hybrid method is presented that is characterized by reduced dynamics in the X-axis and more passes than the rope threading method. A description of the methods using mathematical parameters is developed to optimize the process efficiency. Numerical calculations to select a method and its associated cutting parameters are carried out for exemplary cutting edges, theoretical roughness values, tool life models, and other variables. The obtained results and the optimization algorithm of the process are presented.
We acknowledge institute colleagues, particularly Dr. Inż. Krzysztof Filipowicz and Dr. Inż. Daniel Grochała, for their advice. We also thank Mr. Marek Stelmaszczyk for translating and proofreading, and AJE for English editing.
This work was financially supported by the National Centre for Research and Development (Project INNOTECH/K3/IN3/18/226861/NCBR/14).
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