Optimal Tool Replacement and Cutting Speed Based on a Stochastic Model of Tool Life under Two Failure Modes of Fracture and Wear

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  • 工具が摩耗と欠損の2つのモードで寿命になる場合の経済的切削速度と工具交換時期の研究
  • コウグ ガ マモウ ト ケッソン ノ 2ツ ノ モード デ ジュミョウ ニ ナル バアイ ノ ケイザイテキ セッサク ソクド ト コウグ コウカン ジキ ノ ケンキュウ

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Determining cutting conditions (tool replacement time, cutting speed, and so on) is a critical component for successfully meeting production schedules and economic demands. It is well known that tool life is probabilistic in nature. This paper presents a generalized machining cost model based on a stochastic model of tool life under two failure modes (i.e., fracture or wear) for determining economic tool replacement and cutting speed. An interruption of machining due to in-process sudden tool fracture or excessive tool wear is detrimental in automated machining systems. Not only does it halt production, but it also affects the quality of the machined surface. The workpiece in-process becomes defective. The interruption of the cut results in the loss of valuable time and an increase in production cost. The optimal tool replacement time and cutting speed are prerequisites for the design of an efficient and economical machining system. The losses incurred by tool fracture are different from those incurred by excessive tool wear. This paper formulates a new machining cost model based on the losses arising from tool fracture and in-process excessive tool wear. The distribution of tool life caused by tool fracture or excessive tool wear is given by the competing risk model under the dependent competing causes of failure. Optimal tool replacement time and cutting speed are obtained with the minimum production cost criterion.

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