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Online optimization of a finish turning process: strategy and experimental validation

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Abstract

The present work carries out online optimization of a finish turning process using a fuzzy set-based optimization strategy. The strategy does not require a priori machining models. The proposed optimization strategy is expected to be efficient for the problem with a large number of design variables. It also acknowledges the presence of statistical variation in the process. The experimental demonstration of the proposed strategy is presented for finish turning of cold-rolled steel with TiN-coated carbide tool. The basis of tool life is maximum allowable surface roughness. The strategy of reusing the failed tool by modified cutting conditions is also implemented on the shop floor.

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Authors and Affiliations

  1. Department of Mechanical Engineering, North Eastern Regional Institute of Science and Technology, Nirjuli, Itanagar, 791 109, India

    M. Chandrasekaran & M. Muralidhar

  2. Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati, 781 039, India

    U. S. Dixit

Authors
  1. M. Chandrasekaran
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  2. M. Muralidhar
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  3. U. S. Dixit
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Corresponding author

Correspondence to U. S. Dixit.

Appendix

Appendix

1.1 Evaluation of operating cost (C 0) for machining

Operating cost is sum of the cost involved for labour, electricity, machine depreciation, and machine maintenance. They are evaluated as follows:

  1. 1.

    Cost of labour

    Consider labour cost per day is $12.96 and operator works 8 h per day.

    So, cost of the labour per hour is $7.41/8 = $1.62.

  2. 2.

    Electricity cost

    Consider cost of electricity per kilowatt hour as $0.11. The lathe machine used an 11-kW electric motor.

    So, the cost of electricity per kilowatt hour = $1.22

  3. 3.

    Machine depreciation cost

    Machine depreciation cost is calculated by straight line (SL) method where depreciation is calculated by spreading the cost evenly over the life period of the fixed asset.

    $$ \mathrm{Let}\mathrm{the}\mathrm{cost}\mathrm{of}\mathrm{the}\mathrm{lathe}\mathrm{machine}\mathrm{be}\$24,074,\mathrm{The}\mathrm{life}\mathrm{period}\mathrm{of}\mathrm{the}\mathrm{machine}\mathrm{is}10\mathrm{years}\mathrm{Total}\mathrm{cost}\mathrm{of}\mathrm{depreciation}=\mathrm{Cost}\mathrm{of}\mathrm{the}\mathrm{fixed}\mathrm{asset}/\mathrm{life}\mathrm{period}=\$24,074/10\mathrm{years}=\$2,407.4 $$

    Consider the machine works for 8 h per day for 25 days in a month for each year.

    The depreciation cost per hour = \( \frac{\$2,407.4}{8\times 25\times 12} \) = $1.00

  4. 4.

    Machine maintenance cost

    The maintenance cost includes cost of engine oil, lubrication oil, grease, motor belts, swarf cleaning, etc. Considering all these, the cost of maintenance of one machine per hour is $0.26.

    $$ \mathrm{So},\mathrm{operating}\mathrm{cost}\mathrm{of}\mathrm{the}\mathrm{machine}\mathrm{per}\mathrm{hour}=\mathrm{labour}\mathrm{cost}+\mathrm{electricity}\mathrm{cost}+\mathrm{machine}\mathrm{depreciation}\mathrm{cost}+\mathrm{machine}\mathrm{maintenance}\mathrm{cost}=\$1.62+\$1.22+\$1.00+\$0.26=\$4.1 $$

    Operating cost per minute = $0.068 (say $0.07).

1.2 Evaluation of tool changing cost (C tc)

Tool changing cost involves cost of tool and labour cost involved for the time spent during tool change.

Tool used has four edges and its cost is $10.1.

So, cost per edge is $2.52.

Tool changing time is 1 min (0.016 h). Labour cost involved is $1.62 × 0.016 = $0.026.

So, tool changing cost is $2.546 (say $2.5).

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Chandrasekaran, M., Muralidhar, M. & Dixit, U.S. Online optimization of a finish turning process: strategy and experimental validation. Int J Adv Manuf Technol 75, 783–791 (2014). https://doi.org/10.1007/s00170-014-6171-2

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  • DOI: https://doi.org/10.1007/s00170-014-6171-2

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