Optimization Of Machining Parameters With Consideration Of Tool Adjustment In Turning Operations

Abstract

Tolerancing in design stage and machining parameter optimization in manufacturing stage are related problems which have a great impact on overall production economics of a machining operation. Unfortunately, these problems have been viewed separately causing conflicts between design and manufacturing decisions. While a design decision is to attain a certain part tolerance in the manufacturing stage, the manufacturing decision may be more concerned about economical production and production feasibility. To avoid such conflicting situations, this thesis presents six optimization models which are developed and solved in two stages in order to integrate tolerancing and machining parameters decisions. One model is developed in the first stage. The first- stage model is related to a design problem and provides better part tolerance to be used in the second stage to incorporate tool adjustment decisions into the optimization of machining parameters. Five models are developed in the second stage and are divided into single-machine and multi-machine turning operation problems. For single-machine turning operations, three models are formulated. The first is a single-product multi-pass model considering pass selection for determining optimum cutting speed, feed rate, depth of cut, dimension deviation and number of passes. The second is a single-product multi- pass model considering inventory and setup costs to find optimum cutting speed, feed rate, depth of cut, dimension deviation and batch size.