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Optimization of the face milling operations by the criterion of the maximal productivity rate

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Abstract

The manufacturing industry solves mainly a double problem of high productivity rate and quality of product. This dual task depends on the machining regimes which changes have limitations conditioned by the quality of products machined and the reliability of the machine tool units. Studies of machining processes show the productivity rate of machine tools depends on the cutting speed and reliability of the cutting tools. An increase in the cutting speed decreases the tool life and machining time. The optimal balance of the cutting speed and tool life yields the maximal productivity rate of the machine tool. Recommended machining regimens for cutting tools’ obtained at laboratory conditions do not consider the specificity of work of machine tool units in the manufacturing environment. The publications related to the optimization of machining processes do not consider the specificity of muti-blade cutting tools' work and the reliability of machine tool units. The milling machining processes implement the multi-cutter tool, in which cutters are involved serially. The specificity of the milling tool operation is not fully described in publications. The presented research paper considers a mathematical model for optimal cutting speed by the criterion of the maximal productivity rate for the face milling process.

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Data availability

The authors declare that the data supporting the findings of this study are available within the article.

Abbreviations

c :

Distance for the implementation of machining processes with quality

b :

Empirical constants that depend on the cutter tool material

C :

Empirical constants resulting from regression analysis of the tool life

d :

Depth of cut

D :

Diameter of the face milling tool

F :

Feed rate of the face milling tool

f p :

Feed rate per cuter of the face milling tool

k :

Number of milling toll revolutions for the milling process

L :

Length of the workpiece

m r :

Meantime the change of the milling tool

n :

Rotating speed of the milling tool

p :

Number of cutters (blades) of the face milling tool

Q :

Productivity rate of the machine tool

r m :

Number of changes in the milling tool

T :

Tool life of the face milling tool

t a :

Auxiliary time for the load and unload of the workpiece, the fast motions of the machine units to the workpiece and back, etc.

t m :

Machining time

V :

Cutting speed

\(\sum {\lambda_{i} }\) :

Failure rates for machine tool units

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Acknowledgements

The Kyrgyz State Technical University after I. Razzakov supported the research work for a publication that was performed as part of the employment and without financial support. The authors did not use copyediting or translation services for the preparation of the manuscript.

Funding

The authors declare that this research received no specific grant from any funding agency in the public, commercial, or not-for-profit sectors.

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Authors and Affiliations

  1. Faculty of Transport and Mechanical Engineering, Kyrgyz State Technical University After I. Razzakov, Ch. Aitmatov Av. 66, 720044, Bishkek, Kyrgyzstan

    Ryspek Usubamatov, Cholpon Bayalieva & Tashtanbay Sartov

  2. Faculty of Mechanical Engineering, D. Serikbayev East KazakhstanTechnical University, Protozanov Str. 69, 070004, Ust-Kamenogorsk, Kazakhstan

    Sarken Kapayeva & Gabdyssalyk Riza

Authors
  1. Ryspek Usubamatov
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  2. Cholpon Bayalieva
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  3. Sarken Kapayeva
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  4. Tashtanbay Sartov
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  5. Gabdyssalyk Riza
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Contributions

RU wrote the methodology and compiled the manuscript text, CB wrote the working example, SK, and RG corrected the manuscript text, and TS designed drawings of figures.

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Correspondence to Ryspek Usubamatov.

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Usubamatov, R., Bayalieva, C., Kapayeva, S. et al. Optimization of the face milling operations by the criterion of the maximal productivity rate. Prod. Eng. Res. Devel. 18, 525–531 (2024). https://doi.org/10.1007/s11740-023-01249-9

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