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1. Introduction
In metal cutting application, the process development can be summarized by the following steps:
definition and verification of the Part Program through dedicated software applications (CAM,
Post processor, CNC machine simulator), physical tryout, part inspection on CMM and Part
Program certification (Figure 1). Tool path simulation is commonly adopted in order to obtain a
A further development of this procedure provides an additional step (Figure 2). In this case, the
validation of a part-program through simulation is fundamental to improve the cutting process. A
significant reduction of cutting process time can be achieved with the optimization of material
removal rate along tool path using proper algorithms.
After the simulation, the studied part-program can be optimized with a kinematic algorithm that
operates to keep constant the chip removed volume per time unit. The purpose of this additional
process design step is to improve the cutting process with a significant time reduction through the
optimization of material removal along tool path. This target is pursued using proper algorithm
that operates with the logics called Constant Removed Volume. Every milling operation can be
characterized by specific values of cutting parameters: depth of cut (p) [mm]; tool radial
engagement (b) [mm]; feed per tooth per revolution (az) [mm\tooth-rev]; spindle speed (n) [rpm];
tool diameter (D) [mm]; number of inserts in the tool (z).
Cutting speed Va is defined by Equation 1:
π Dn
Va = [m\min] (1)
1000
The relationships among cutting parameters isdefined by Equation 2:
Va = n ⋅ az ⋅ z [mm\min] (2)
These parameters determine the amount of material removal during tool path; removed material
volume (Q) is defined by Equation 3:
In the kinematic optimization method, b and p in Equation 3 are constant and assigned to obtain
the best use of the tool in accordance with tool producer indications, so optimization algorithm
modifies Va to respect the constancy of removed volume and to respect the fixed value of b and p.
It is important to notice that the optimization procedure does not modify the tool path but, it can
produce some breaks in the path depending on the local quantity of material that has to be
removed. Spindle speed is considered constant (Del Prete, 2009). In this paper a new
multidisciplinary procedure is proposed (Figure 3). The already illustrated workflow is integrated
with a finite element cutting simulation environment where it is possible to predict the physical
effects arising from the cutting process: cutting forces and cutting edge temperatures .
The aim of the authors is to modify the operation parameters set in the already kinematically
optimized Part Program according to the constraints arising from the physical nature of the cutting
process obtained by FEA. In particular, tool wear is known to be strictly linked to the cutting
temperature and to the exchanged forces between insert and workpiece. Being able to know the
values of these forces during the process it allows to select optimal input parameters, in this way it
is possible to reduce the time frame required by the process and it allows to control the tool wear.
The optimization procedure uses Response Surfaces properly produced according to data calculate
with FEM simulations and experimental tests carried out on the base of a DOE of the variables
(input parameters) which have influence on the analyzed responses (Figure 4). The advantage of
these techniques, compared to the traditional ones, is that it is required to know the exact response
function of the system only in certain points of the design space and from these points it is
possible to extract, thanks to the response surface, the needed values in all the other points. These
results produce significant benefits in reducing the calculation time as the optimization process
does not require continuous and repeated calls to the solver, but it can exploit the data provided by
the approximation response surface. Optimization of machining parameters not only increases the
utility for machining economics, but also the product quality to a great extent. In this study,
approximation models based on RBF methodology has been developed to predicting the behaviour
of analyzed responses and to create a multidisciplinary optimization procedure.
The maximum force calculated at the interface tool- workpiece it occurs when the tooth surface
impacts on the workpiece. To detect the force components, Fx and Fy (Figure 6-A), a simplified
2D model has been chosen (Figure 6-B). In this case the real feed per tooth is the DOC on the
ε T − Troom
m
( )
σ eq = A + Bε n 1 + C ln 1 −
ε0 Tmelt − TRoom
(5)
where ε is the plastic strain, ε is the strain rate (s-1), ε0 is the reference plastic strain rate (s-1).
T is the material temperature (°C), Tmelt is the melting material temperature (1400 °C) and Troom is
the room temperature (20 °C). Coefficient A is the yield strength (MPa), B is the hardening
modulus (MPa), C is the strain rate sensitivity coefficient, n is the hardening coefficient and m the
thermal softening coefficient (Uhulmann,2007).
3. Case Study
A CCOC (Combustor Chamber Outer Casing) of an aeronautical engine in Inconel 718 has been
chosen to test the developed methodology. A part program that involves the use of milling
operations has been selected; this operation involves the use of two rough and seven finish tools.
The related Part Program which has about 15000 instruction blocks has been simulated and the
machining time has been computed. In Figure , it is reported the machining operation sequence: 1)
Pocket opening; 2) Chamfer roughing; 3) Pocket milling.
Part Program obtained whit standard CAD-CAM procedure has been subjected to kinematic
optimization: this operation has as output a new Part Program. The new simulation predicted a
reduction in machining time of 48% compared to the not optimized Part Program. This reduction
is obtained increasing the F values but, the tool path trajectory is the same of the original Part
Program. The performed kinematic optimization does not take into account the physical
interaction between tool and workpiece. In the proposed multidisciplinary procedure the feed and
speed indicated in the obtained Part Program thanks to the kinematic optimization have to be
extracted and compared with the response surface in terms of temperature and forces generated
(Figure 9) (Del Prete, 2009).
The multidisciplinary optimization tool draws F and S values from the kinematic optimized Part
Program and converts them into the required measure units of the response surface. In the Part
Program, F and S are respectively expressed in [m\min] and [rpm] and it is necessary to convert
them into [mm\tooth-rev] and [mm\s]. So proper equivalent relationships, Equation 6 and
Equation 7 have been used to obtain the correct parameters expressions:
F S ⋅π ⋅ D
f = [mm\tooth-rev] (6) ; Vt = [mm\s] (7)
S⋅z 60
The obtained values of az and Vt have been introduced in the response surfaces. The correspondent
temperature, forces and surface roughness have been detected. This outputs must be less then the
given fixed physical constraints. If the correspondent values of cutting edge temperature Tmax , Fx
, Fy for a single az exceeded the established limits an inferior value has been considered in
compliance with the fixed limits of Tmax , Fx , Fy. The optimized f values, have been reconverted in
the unit of measure adopted in the Part Program and rewritten in the correspondent block of the
optimized Part Program (Figure 10).
The procedure requires two input files: the part program created by the user (of course consistent
with the Vericut project file) and the Vericut project file that defines the simulation configuration.
in Vericut environment . The procedure returns as output Excel files containing information of a
post-processing and the optimize part program according to the imposed constraints about cutting
parameters and tools wear life (Figure 12). The files returned from the procedure are:
• Template_cambut: the Excel report on the changes included in the tool part-program
• Total_Time: table containing the total time of different analyzed part-program
• PPfile_optimized_RSM: optimized part-program.
The data about micro-scale physical cutting conditions for each tool, obtained through FEM
simulations, are contained in an Excel file, which has a name like:
RSM_UT_ <Tool id>. Xls, for example RSM_UT_55.xls
In this study the authors have used the RSM developed on the base of data obtained by FEM
calculations to represent the behaviour for the analyzed responses for all the tools used in the
analyzed PP. For each tool the process parameters design space has been adequate to its operative
range. All Excel files relating to the data obtained for each tools have been grouped in a zip file
and stored within the model.
4. Conclusion
The presented application can be considered an effective procedure for the introduction, in the Part
Program previously optimized in terms of kinematic information, of the physics of the cutting
process (cutting edge temperature and forces exchanged between tool and workpiece). The
physical quantities were detected using response surfaces generated from data extracted from FEM
simulations performed on the basis of a DOE study. Three tool paths simulations have been ran
and the execution times have been compared in the case of: 1) Non optimized Part Program; 2)
Kinematic Optimized Part Program; 3) Optimized Part Program based on process parameters
selected in the kinematic optimization but updated with values for F and S parameters value
respecting the given physical constraints (Figure 13). The obtained results showed that the
kinematic optimization dramatically decreases the execution time of the analyzed Part Program
(reduction of 52% respect CAM PP). Moreover, the introduction of physical constraints reduces
this percentage to 18% but at the same time it allows to meet the technological constraints set to
control the tool wear. The CAE-CAM optimization (OPTI-CAE in Figure 13) has lowered many
of values (F and S ) present in the PP optimized kinematically (OPTIPATH in Figure 13). This has
caused an increase in processing time by 42% compared to the one required by the kinematically
optimized PP. As next step the authors will focus their efforts on the search of the numerical -
experimental correlation of the FEM models to improve the reliability of the RS models. Another
5. References
A. Del Prete, A. Spagnolo, A. A. De Vitis, A. Anglani "Experimental evaluation of the influence
of part program optimization algorithms on surface roughness in milling operation" - 9st
AITeM Conference – Torino, Italy, 2009
A. Weissinger. "Lift distribution of swept-back wings". NACA pp.1120, 1947.
ENGINEOUS SOFTWARE - iSIGHT Version 3.0 User's Guide - 2008.
A A Del Prete, A.A. De Vitis, D. Mazzotta, “Design space investigation by RSM Techniques in
Aeronautical Metal cutting Applications” - OPTI 09 Algarve, Portugal , 2009
E. Uhlmann, Finite Element Modeling and Cutting Simulation of Inconel 718. CIRP Annals -
Manufacturing Technology, 56(1), pp. 61-64, 2007.
A. Del Prete, A.A. De Vitis, D. Mazzotta, M. Cherubini “Metal Cutting simulation as support tool
to Product and Process development of aeronautical components in Inconel 718” - 10th CIRP,
Scilla, Italy, 2007.
A. Del Prete, A.A. De Vitis, D. Mazzotta, A. Anglani “Numerical Simulation of Broaching
Process in Aeronautical Applications” - AMST'08 8th – Udine, Italy, 2008
A Del Prete, A.A. De Vitis, A. Spagnolo, D. Mazzotta, “Cutting Parameters Optimization through
an advanced CAE-CAM procedure” - NAFEMS WC 09 Crete, Greece, 2009
A Del Prete, A.A. De Vitis, A. Anglani, “Roughness inprovement in machining operations
through coupled metamodel and genetic algorithms technique” - 13 th Esaform Conference -
Brescia, Italy, 2010
A Del Prete, A.A. De Vitis, A. Spagnolo, “Experimental development of rsm techniques for
surface quality prediction in metal cutting applications” - 13 th Esaform Conference - Brescia,
Italy, 2010.