A procedure to obtain mill cutter and cutting parameters using parameter optimization under constraints and expert rules

In this paper, remove material processes are into account for developing an expert mill cutter and cutting parameters selection system based on numerical methods of performance evaluation. The knowledge base is given by limitations in process variables, which let us to define the allowable cutting parameter space. The mentioned limitations lead to instabilities due to tool-work-piece interaction, known as chatter vibrations. The power available in the spindle motor and milling force control restrictions are also considered as process limitations. Moreover, an additional term is taken into consideration in order to be sure of avoiding chatter vibrations when the spindle speed is varied due to spindle deflexions or perturbations. Then, a novel tool cost model is contrived. It is used to choose a suitable tool, among a known set of candidate available cutters, and to obtain the appropriate cutting parameters in an optimal way. Once the tool and the cutting parameters are obtained, the developed system is able to redefine the cutting parameters automatically if new considerations about machinery data are required through expert rules. Nevertheless, such optimal cutting parameters can be obtained by introducing into the system production and/or machine tool constraints and/or by manipulating the cost function weighting factors. An example is presented in order to illustrate the method.