Optimization of machining processes by using criteria of maximum productivity and minimum cost

In manufacturing, the machining process by using norms of the maximum productivity and minimum cost is knotted. In many cases, the increase of machining modes leads to an increase in productivity, and the machining cost also increases. The present thesis formulates a set of mathematical models that...

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Main Author:	Aead, M. Ahmed
Format:	Thesis
Language:	English
Subjects:	Machining process Machine tools Machining mode Optimization Cost effectiveness Maximum productivity
Online Access:	http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/31212/1/Page%201-24.pdf http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/31212/2/Full%20text.pdf
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spelling	my-unimap-312122014-01-15T02:44:22Z Optimization of machining processes by using criteria of maximum productivity and minimum cost Aead, M. Ahmed In manufacturing, the machining process by using norms of the maximum productivity and minimum cost is knotted. In many cases, the increase of machining modes leads to an increase in productivity, and the machining cost also increases. The present thesis formulates a set of mathematical models that enable the setting of maximum productivity and minimum cost parameters on machine tools. Three new mathematical approaches have been developed to achieve this objective. In the first approach, maximum productivity is given as a function of the increase of cutting speed at (x) time equal 0.93. The second approach focuses on optimizing multi tool machining process with simultaneous actions. Here, the maximum productivity at (k) factor, which is 1.28 of changing the cutting speed, has been derived. Whereas in the third approach, maximum productivity and minimum cost for single and multi tools are presented. The equations are useful in modeling and predicting the processing mode that will give maximum productivity and minimum cost. By keying in the developed mathematical expressions in MATLAB, the productivity of the machine tool is calculated. This work has been carried out under dry conditions. The results give the optimum cutting speed (Vopt) at maximum productivity for a single cutting tool for high speed steel and carbide as a theoretical. Whereas by keying a diameter of work piece is 25mm, depth of cut 2mm and feed rate 0.21mm/rev, which are achieved experimentally, the proper cutting speed for HSS of the tested materials is 50 m/min. whereas the optimum cutting speeds of cutting tool machining process of the different materials as a theoretical of maximum productivity for cemented carbide is 95 m/min. whilst for the multi cutting tool of the same materials the maximum theoretical productivity is obtained at 80 m/min. whereas the optimum cutting speeds for the multi cutting tool machining process of the same materials as an experimental for maximum productivity at 75 m/min. However, increasing the machining regimes leads to an increase in both of machining cost and productivity. In the minimum cost approach, which is a proper cutting speed of the tested materials is 46 m/min. The convenient range values of multi-cutting speed for both productivity and cost obtained in this work is 40 to 90m/min, and a favorable range of cutting speed is 40 to 60 m/min to get the minimum cost. The appropriate range of cutting speed of the mathematical model for the productivity for single and multi -cutting tool for intermediate hardness of work piece material is 35 to 69 m/min, 50 to 90m/min, respectively. Although both theoretical and experimental data sets show similar behavior, there are slight deviations within acceptable range for the two data set values. Universiti Malaysia Perlis (UniMAP) 2013 Thesis en http://dspace.unimap.edu.my:80/dspace/handle/123456789/31212 http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/31212/1/Page%201-24.pdf 4ea4cf58a4b5662929d8f011270f461a http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/31212/2/Full%20text.pdf 10c417589946d9702cda59772e8eef44 http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/31212/3/license.txt 8a4605be74aa9ea9d79846c1fba20a33 Machining process Machine tools Machining mode Optimization Cost effectiveness Maximum productivity School of Manufacturing Engineering
institution	Universiti Malaysia Perlis
collection	UniMAP Institutional Repository
language	English
topic	Machining process Machine tools Machining mode Optimization Cost effectiveness Maximum productivity
spellingShingle	Machining process Machine tools Machining mode Optimization Cost effectiveness Maximum productivity Aead, M. Ahmed Optimization of machining processes by using criteria of maximum productivity and minimum cost
description	In manufacturing, the machining process by using norms of the maximum productivity and minimum cost is knotted. In many cases, the increase of machining modes leads to an increase in productivity, and the machining cost also increases. The present thesis formulates a set of mathematical models that enable the setting of maximum productivity and minimum cost parameters on machine tools. Three new mathematical approaches have been developed to achieve this objective. In the first approach, maximum productivity is given as a function of the increase of cutting speed at (x) time equal 0.93. The second approach focuses on optimizing multi tool machining process with simultaneous actions. Here, the maximum productivity at (k) factor, which is 1.28 of changing the cutting speed, has been derived. Whereas in the third approach, maximum productivity and minimum cost for single and multi tools are presented. The equations are useful in modeling and predicting the processing mode that will give maximum productivity and minimum cost. By keying in the developed mathematical expressions in MATLAB, the productivity of the machine tool is calculated. This work has been carried out under dry conditions. The results give the optimum cutting speed (Vopt) at maximum productivity for a single cutting tool for high speed steel and carbide as a theoretical. Whereas by keying a diameter of work piece is 25mm, depth of cut 2mm and feed rate 0.21mm/rev, which are achieved experimentally, the proper cutting speed for HSS of the tested materials is 50 m/min. whereas the optimum cutting speeds of cutting tool machining process of the different materials as a theoretical of maximum productivity for cemented carbide is 95 m/min. whilst for the multi cutting tool of the same materials the maximum theoretical productivity is obtained at 80 m/min. whereas the optimum cutting speeds for the multi cutting tool machining process of the same materials as an experimental for maximum productivity at 75 m/min. However, increasing the machining regimes leads to an increase in both of machining cost and productivity. In the minimum cost approach, which is a proper cutting speed of the tested materials is 46 m/min. The convenient range values of multi-cutting speed for both productivity and cost obtained in this work is 40 to 90m/min, and a favorable range of cutting speed is 40 to 60 m/min to get the minimum cost. The appropriate range of cutting speed of the mathematical model for the productivity for single and multi -cutting tool for intermediate hardness of work piece material is 35 to 69 m/min, 50 to 90m/min, respectively. Although both theoretical and experimental data sets show similar behavior, there are slight deviations within acceptable range for the two data set values.
format	Thesis
author	Aead, M. Ahmed
author_facet	Aead, M. Ahmed
author_sort	Aead, M. Ahmed
title	Optimization of machining processes by using criteria of maximum productivity and minimum cost
title_short	Optimization of machining processes by using criteria of maximum productivity and minimum cost
title_full	Optimization of machining processes by using criteria of maximum productivity and minimum cost
title_fullStr	Optimization of machining processes by using criteria of maximum productivity and minimum cost
title_full_unstemmed	Optimization of machining processes by using criteria of maximum productivity and minimum cost
title_sort	optimization of machining processes by using criteria of maximum productivity and minimum cost
granting_institution	Universiti Malaysia Perlis (UniMAP)
granting_department	School of Manufacturing Engineering
url	http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/31212/1/Page%201-24.pdf http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/31212/2/Full%20text.pdf
_version_	1747836776579334144

Optimization of machining processes by using criteria of maximum productivity and minimum cost

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