Dynamic modeling and approach of optimum MRR and tool life control

The dynamic modeling with optimum material removal rate (MRR) control and tool life determination through Calculus of Variations to minimize the machining cost of a cutting tool under expected machining quantity are developed. The advantage of this study is demonstrated through a numerical example from the real-world CNC industry with BORLAND C++ BUILDER. The theoretical and simulated results are shown in good agreement. To analyze the machining process, the dynamic approach of MRR control is experimentally realized on ECOCA PC-3807 CNC lathe with VERDURE PA-100 controller connected to an IBM PC 586 microprocessor through RS-232. The surface roughness of all machined workpieces is found acceptable within the standard for finish turning. The dynamic MRR optimization for multi-operation and multi-tool CNC machining process in achieving the minimum manufacturing cost can then be extended. Significance: The theoretical solution and experimental approach of dynamic MRR optimization with tool life policy for individual CNC cutting tool are successfully proposed in this study.