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124699

Database for Optimal Selection of Cutting Conditions, Forces and Power Consumption in Machining Processes.

Article

Last updated: 22 Jan 2023

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Subjects

-

Tags

Mechanical Power Engineering

Abstract

Selecting the cutting data (cutting speed, feed, depth of cut) and the proper cutting tools play a significant role in achieving minimum production time, consistent quality and in controlling the overall cost of manufacturing. However, searching for a proper tool/insert-job combination calls for a huge amount of data and an extensive knowledge base and may take a long time and effort if it is done manually. In this paper, a software has been designed and established using Microsoft Visual Basic.Net and SQL server to store all different types of tool grades with their available cutting data, inserts, and tool holders for all materials and some machining operations (turning, drilling and milling) in a database. The software is capable of selecting the suitable cutting data, tool grade, insert and tool holders for each operation in two cases. The first case uses the maximum cutting speed of the tool grade (minimum tool life) while the second case uses the minimum cutting speed (maximum tool life). In the two cases, the software considers the constraints of power, efficiency, and maximum spindle revolution of the machine as well as the required surface roughness of the workpiece. The software is capable of calculating the machining time, intermittent time, force, torque, power, spindle revolution and total production time and cost for each operation. In addition, the workpiece material, required operations, cutting data, force, torque, power, the suitable tool grade and its manufacturer, insert and tool holder are displayed in a single report as a process sheet. Another report can be used to show the total production time and the total cost. A case study has been done to test the proposed software and it was found that about 34% of the total production time could be saved by using the maximum cutting speed, compared with the minimum cutting speed. On the other hand, about 28% of the total production cost could be saved by using the minimum cutting speed, compared with the minimum cutting speed. 

DOI

10.21608/bfemu.2020.124699

Keywords

cutting conditions, databases, Machining processes, optimal selection, Power consumption

Authors

First Name

A.

Last Name

El Bahloul

MiddleName

M.

Affiliation

Professor of Production Engineering and Mechanical Design Department., Faculty of Engineering., El-Mansoura university., Mansoura., Egypt.

Email

elballoul@hoinall.com

City

Mansoura

Orcid

-

First Name

I.

Last Name

Eleva'

MiddleName

M.

Affiliation

Dean of High Institute of Engineering and Technology, Mansoura, Egypt.

Email

-

City

Mansoura

Orcid

-

First Name

Fatma

Last Name

Elerian

MiddleName

-

Affiliation

Assistant Professor., Production Engineering and Mechanical Design Department., Faculty of Engineering.. Mansoura University., Mansoura., Egypt.

Email

fatmaelerian@mans.edu.eg

City

Mansoura

Orcid

0000-0002-7375-6621

First Name

E.

Last Name

Gadelmawla

MiddleName

-

Affiliation

Associate Professor., Production Engineering and Mechanical Design Department., Faculty of Engineering., El-Mansoura University., Mansoura., Egypt.

Email

esamy@motus.edu.eg

City

Mansoura

Orcid

-

Volume

35

Article Issue

1

Related Issue

17860

Issue Date

2010-03-01

Receive Date

2010-01-11

Publish Date

2020-11-22

Page Start

103

Page End

113

Print ISSN

1110-0923

Online ISSN

2735-4202

Article File

BFEMU_Volume 35_Issue 1_Pages 103-113.pdf

PDF . 1.5MB

Link

https://bfemu.journals.ekb.eg/article_124699.html

Detail API

https://bfemu.journals.ekb.eg/service?article_code=124699

Order

31

Type

Research Studies

Type Code

1,205

Publication Type

Journal

Publication Title

MEJ. Mansoura Engineering Journal

Publication Link

https://bfemu.journals.ekb.eg/

MainTitle

-

Details

Type

Article

Created At

22 Jan 2023