Analysis: Machining Economics

How can we optimize the machining of a part ?

Identify the objective, formulate a model, solve for optimality

Typical objectives: maximum production rate, and/or minimum cost

Are these objectives compatible (satisfied simultaneously) ?

Formulating model: observations hypothesis theory model

Analysis: Machining Economics..

Formulating model: observations hypothesis theory model
Observation:
A given machine, tool, workpiece combination has finite max MRR
Hypothesis:
Total volume to cut is minimum Maximum production rate
Model objective:
Find minimum volume stock for a given part
-- Near-net shape stocks (use casting, forging, )
-- Minimum enclosing volumes of 3D shapes
Models:
- minimum enclosing cylinder for a rotational part
- minimum enclosing rectangular box for a milled part
Solving:
-- requires some knowledge of computational geometry

Analysis: Machining Economics..

Model objective:
Find optimum operations plan and tools for a given part

Example:

or

or
??
Model: Process Planning
- Machining volume, tool selection, operations sequencing
Solving:
- in general, difficult to optimize

Analysis: process parameters optimization

Model objective:
Find optimum feed, cutting speed to [maximize MRR]/[minimize cost]/
Feed:

Higher feed higher MRR

Finish cutting:

surface roughness feed

Given surface finish, we can find maximum allowed feed rate

Process parameters optimization: feed

Rough cutting:
MRR cutting speed, V
MRR feed, f

cannot increase V and f arbitrarily

V MRR;
Tool temperature V, f;
For a given increase in MRR:

V lower tool life than f

Optimum feed: maximum allowed for tool [given machine power, tool strength]

Process parameters optimization: Speed

Model objective:
Given optimum feed, what is the optimum cutting speed

provided upper limits, but not optimum

Need a relation between tool life and cutting speed (other parameters being constant)
Taylors model (empirically based): V tn = constant

Process parameters optimization: Speed

One batch of large number, Nb, of identical parts
Replace tool by a new one whenever it is worn
Total non-productive time = Nbtl
tl = time to (load the stock + position the tool + unload the part)
Nb be the total number of parts in the batch.
Total machining time = Nbtm
tm = time to machine the part
Total tool change time = Nttc
tc = time to replace the worn tool with a new one
Nt = total number tools used to machine the entire batch.

Cost of each tool = Ct,

Cost per unit time for machine and operator = M.

Average cost per item:

C pr

Nt
Nt
Mt l Mt m M
tc
Ct
Nb
Nb

Process parameters optimization: Speed

Average cost per item:

C pr

Nt
Nt
Mt l Mt m M
tc
Ct
Nb
Nb

Let: total length of the tool path = L

L
tm
V

L
MLV 1
V

t = tool life Nt = (Nb tm)/t Nt / Nb = tm / t

Taylors model

Vtn = C

t = C 1/n / V1/n = C/V1/n

Nt
tm
L V (1n ) / n
L V 1/ n

Nb
t
V C
C

Process parameters optimization: Speed

Average cost per item:

C pr

Nt
Nt
Mt l Mt m M
tc
Ct
Nb
Nb

L
M MLV 1
V
Nt
L V (1n ) / n

Nb
C

C pr

L
Mtl MLV ( M t c Ct ) V (1n ) / n
C
1

Process parameters optimization: Speed

C pr

L
Mtl MLV ( M t c Ct ) V (1n ) / n
C
1

Optimum speed (to minimize costs)

dC pr
dV

0 MLV

L
(1 n) (1 2 n ) / n
( M t c Ct )
V
C
n

MC
n

V *
( M tc Ct ) (1 n)

Optimum speed (to minimize time)

Average time to produce part: t pr

Nt
tl t m
tc
Nb

Process parameters optimization: Speed

Optimum speed (to minimize costs)

MC
n

V *
(
M
t

C
)
(
1

n
)
c
t

Optimum speed (to minimize time)

Average time to produce part:

t pr

load/unload time

Nt
tl t m
tc
Nb
tool change time

machining time

t pr

Nt
tl t m
tc
Nb
L
tm
V

Nt
L V (1n ) / n

Nb
C

Substitute, differentiate, solve for V*