Optimization strategy for turning operation accounting for cutting tool wear history

The paper reports on a methodology for monitoring and evaluating the progress of cutting tool wear and an optimization strategy for turning operations in which the progress of cutting tool wear is taken into account in optimizing process parameters. The methodology evaluates tool wear history’ when a cutting tool is used under different process conditions (e.g. change in workplace material and range of cutting parameters) which a cutting tool is likely to encounter in small batch production operations. The optimization strategy proposed attempts to maximize material removal rate taking into account surface roughness, system stability and cutting tool failure as its technical constraints. One of the novel aspects of this work is that it enables a more complete tool failure avoidance strategy to be developed, taking into account tool wear progression under a variety of conditions. The machining strategy is aimed at optimizing batch production in turning where it is likely that the same cutting tool edge is used to process parts made of different workpiece materials and therefore the cutting tool reaches its limiting flank wear under variable sets of cutting conditions.