Purpose: This paper is focused on the optimal cutting parameters design of rough cutting processes in side milling for SKD61 tool steels. Design/methodology/approach: The fuzzy logics can be a proper basis to perform the optimization procedure with complicated multiple performance characteristics in this paper. Using this approach combined with the grey-relational analysis, the design algorithm is transformed into optimization of a single and simple grey-fuzzy reasoning grade rather than multiple performance characteristics. The Taguch method is also adopted to search for an optimal combination of cutting parameters for this rough cutting process in side milling. Findings: The improvement of tool life and metal removal rate from the initial cutting parameters to the optimal cutting parameters are 54% and 9.7%. Hence, this reveals that the proposed approach in this study can effectively improve the cutting performance. Research limitations/implications: In this paper only four cutting parameters are taken into consideration. Many other parameters such as tool geometric shape are not applied to this study. Practical implications: It is believed that this optimal result can be applied to practical processes to effectively reduce manufacturing cost and greatly enhance manufacturing efficiency. Originality/value: A systematic and effective optimization method is presented in this paper. Using this method can effectively acquire an optimal combination of the cutting parameters.
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Purpose: The main purpose of this paper is to analyse the grinding processes and develop a search system of database for cutting tools. Design/methodology/approach: A tool grinding software with open architecture was used to analyse the grinding processes of square end mills, tapered square end mills, ball nose end mills, tapered ball nose end mills, radius end mills, tapered radius end mills, straight flute reamers, helical flute reamers, flat drills, twist drills, and step drills. According to the characteristics of these tools, 20270 data were established in the relational database. The SQL syntax was then utilized for writing the search algorithm, and the C++ Builder was employed for designing human machine interfaces of the search system of the tool database. Findings: A half of time on the tool design and the change of production line for grinding other types of tools can be saved by means of the proposed system. More specifically, the efficiency in terms of the overall machining time was improved up to 10.58%, 9.36%, 4.64%, and 7.52% for grinding the radius end mill, tapered radius end mill, twist drill, and step drill, respectively. Research limitations/implications: Special tools have diversification. They can not be taken into consideration in the database system owing to the tools have specific profiles. Therefore, it is difficult to encode by formal rules. Practical implications: The most commercial tool grinding software is the modular-based design and uses tool shapes to construct the CAM interface. However, it is very difficult for users to design new cutting tools. Utilizing the grinding processes to construct the grinding path of tools, and the search system of the database provides more flexible options to develop new cutting tools. Originality/value: The database and search system of cutting tools were presented in this paper. We can save time for production line change, tool design, and tool grinding by employing this kind of system. It also gives more convenience. That is, company's productivity and benefit can be improved.
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