Abstract
Abstract
It has long been recognized that the selection of cutting conditions in process planning should optimize the economic performance of machining operations although it appears that common practice favours the use of ‘recommended’ cutting conditions which are known to be non-optimal. This practice seems to be partly due to the difficulties in establishing equations for the many technological machining performance measures and partly due to the complex nature and slow progress made in developing reliable multi-constraint optimization analyses. This paper presents multi-constraint optimization analyses and computer aided strategies for selecting the ‘optimal’ feeds and speeds in single-pass rough turning operations. The optimization, based on criteria typified by the minimum time and cost per component and suitable for the newer coated lathe tools with in-built chip breaker groove designs, incorporates chip breaking constraints for turning on computer numerical control (CNC) lathes. Despite the complexity of the analyses, clearly denned strategies that guarantee the global optimal solutions have been developed. Extensive simulation studies have highlighted the considerable economic benefits of using ‘optimal’ rather than ‘recommended’ cutting conditions, the potential for increased benefits from improved chip control and tool magazine designs and the need for technological performance equations as well as optimization analyses for the wide spectrum of machining operations for use in modern process planning.