Abstract
The paper describes the practical effects of the operating parameters in the milling operation. Experiments have been conducted to measure cutting force and tool life under dry conditions. Based on the experimental results, three mathematical models have been developed: Force, TLife and Force/TLife. Further analyses have been conducted on the cutting force patterns: seasonal pattern and nonlinear trend. A process optimisation that is based on the minimum production cost has been applied to relate Force model, TLife model and machinability criteria, such as power consumption, cutting parameters and surface roughness.
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Abbreviations
- C w :
-
cost of workpiece ($)
- C s :
-
set-up cost ($)
- C m :
-
machining cost ($)
- C o :
-
overhead cost ($)
- C r :
-
tool replacement cost ($)
- C t :
-
tool cost ($)
- D :
-
diameter of the cutter (inch)
- d :
-
depth of cut per pass (inch)
- d 0 :
-
required depth (inch)
- e t :
-
random error attth sample
- F :
-
cutting force (N)
- f :
-
feedrate (ipm)
- L :
-
length of workpiece (inch)
- N :
-
spindle speed (r.p.m.)
- n :
-
number of teeth
- P :
-
power of the motor (h.p.)
- R :
-
surface roughness (µm)
- R e :
-
real part of a complex function
- T :
-
tool life (min)
- t :
-
sample number
- t m :
-
machining time (s)
- t 0 :
-
overhead time (s)
- t r :
-
tool replacement time (s)
- t s :
-
set-up time (s)
- U i :
-
unit cost of itemi ($/unit)v
- v :
-
cutting speed (i.p.m.)
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