Optimum machining performance in finish turning with complex grooved tools

This paper presents a methodology to achieve optimum selection of cutting conditions and tool inserts for finish turning operations. It utilizes classic metal cutting theories and an expandable database of experimental results to describe the interrelationships between the multiple performance objectives and the multiple process variables which govern the machining process involving the use of complex grooved tools. Major machining performance characteristics, including surface roughness, curing force, tool-life, chip breakability and material removal rate, are considered by choosing one as the optimization objective and the others as constraints. Nonlinear programming techniques coupled with numerical methods for data interpolation are applied to identify optimum process conditions. A PC-based, menu-driven program has been developed for the application of this new methodology. Numerical results show that the methodology can be used to considerable advantage in specifying the machining variables.