Real Time Optimization and Automatic Manipulation of Machining Parameters Through Adaptive Control Method

Abstract

newline quotThis research work aims to provide an overview of the various methods for evaluating cutting tool efficiency specifically for the turning operation. The cutting operation variables like cutting speed, feed rate, and depth of cut have to be selected cautiously during the turning operation to increase profitability by increasing efficiency and lowering overall manufacturing costs for each part. High vibration causes poor surface finish, lower efficiency, and shorter tool life; as a result, this parameter should be kept under control. newlineThe performance of the cutting tool while turning operation depends on the material strength, structural design, and attachment configuration. For different configurations such as simply supported and fixed (clamped) end, the structural strength of the tool varies along the length of the cutting tool. The present work encompasses the structural analysis of cutting tools in two different conditions of simply supported and fixed-end conations utilizing numerical simulation techniques. The analysis shows that the stress distribution of the simply supported condition from minimum to maximum variations along the length of the tool periodically; whereas the fixed/clamped scenario leads to the maximum value at the end of the tool other than the clamped one along with the distributions of the minimum to mid-range values along the length of the cutting tool. newlineThe performance of the cutting tool subjected to vibration depends upon the operational parameters of the systems. Experimentation is the most reliable means of investigating the vibration behavior of the cutting tool during the turning operation on the workpiece. However, the empirical expressions developed based on the well-designed experimental observations give many reliable predictions. Hence, the core objective of the present study is to apply the design of experiment (DOE) approach on the vibration study of cutting tool considering the four key variables: rotational speed (N) of the spindle i.e. work-piece, feed rate