The Determination of The Optimal Combination of Processing Mode Parameters Based On The Machinability Criterion "Optimal Material Removal Rate"

International Journal of Application or Innovation in Engineering & Management (IJAIEM)
Web Site: www.ijaiem.org Email: editor@ijaiem.org

Volume 9, Issue 7, July 2020 ISSN 2319 - 4847
The determination of the optimal combination

of processing mode parameters based on the
machinability criterion “optimal material
removal rate”
Valentin I. Svirschev1, Alexey N. Savlov1, Stepan V. Tarasov1,
The Department for Innovation Technologies of Machine Engineering, Рerm national research polytechnic university,
Academika Koroleva st., 15-309 Perm, 614013, Russia
Abstract
Manufacturers of cutting tools offer a large number of recommendations to choose combinations of parameters for
processing the same elementary surfaces of a part. These recommendations make it difficult to select and assign controlled
parameters of the cutting mode as they depend on a large number of factors, and therefore specialists who are involved in
the design of technological documentation and the development of control programs for multi -operational CNC machines
have problems. Based on the selected generalized machinability criterion “optimal material removal rate”, combinations of
controlled parameters of the cutting mode with a tool are established in all ranges of changes in the recommended
parameters of the regime for each processing stage. The combination of controlled parameters of the cutting mode for
various processing methods for the adopted tool life T, which provide the optimal material removal rate Q0, was calculated.
The methodology and maps have been developed for the optimal combination of controlled cutting parameters of various
processing methods for the adopted tool life. The maps of the optimal combination of parameters for the processing of
elementary surfaces are normative guidance materials for technologists in the development of technological processes for
the manufacture of parts and programmers in the development of control programs for multi-operational CNC machines.
Keywords: machining, cutting tool, material removal rate, tool life, T-Q characteristic of the cutting process, optimal
combination of processing mode parameters.
1. INTRODUCTION
Designing the operations of machining the surfaces of machine parts on multi - operational CNC machines requires a
reasonable choice of a cutting tool and combinations of controlled processing parameters that provide the necessary
quality indicators of the machined surfaces for accuracy and roughness [1]-[3]. Official reference literature [4, 5] and
metalworking guides of various cutting tool manufacturers such as Sandvik, Seco, Iscar, TaeguTec, Kennametal,
Hanita, Mitsubishi, Vergnano recommend different combinations of cutting parameters to process elementary surfaces.
These parameters are recommended for tools with optimal geometry of their cutting parts. They also depend on the
groups of workability of materials, the processing stage (rough, finishing), the material of the cutting part, the tool life,
the condition of the initial workpiece and technological equipment.
2. PROCESSING EFFICIENCY AND MACHINABILITY CRITERION
A large number of recommendations to choose the parameters of cutting conditions during machining of the same
elementary surfaces of parts with cutting tools of different manufacturers [6]-[12] do not take into account the
efficiency of processing elementary surfaces for given technological conditions to manufacture parts ensuring the
required quality.
The effectiveness of machining depends on the combination of parameters of the cutting mode, the tool life, the time it
takes to replace the tools. When the parameters of the cutting mode rise, the machine time decreases, which leads to a
reduction in the tool life, and therefore, to an increase in the cutting tools costs. At a certain point in time, these costs
become those that contribute to an increase in cost and a decrease in processing productivity. Most often, such
situations arise during the machining of difficult-to-process materials, and determine the quality indicators and surface
machining productivity.
Solutions for the preliminary calculation of the controlled parameters combination for cutting according to the
optimality criteria chosen from the groups of technical and economic criteria are known [13]-[16]. These solutions
contribute to significant improvement of the quality of processed elementary surfaces, but nevertheless, they do not
provide the necessary effectiveness of surface machining. This is due to the fact that when solving problems of
optimizing cutting conditions, the optimization model does not include technical limitations that would take into
Volume 9, Issue 7, July 2020 Page 50

account the dependence of the tool life on the controlled parameters of the processing mode, which in turn determine
the material removal rate during machining. This does not allow using the potential opportunities to increase the
efficiency of machining processes at the lowest cost and to ensure the necessary indicators of the processed elementary
surface quality.
When cutting with a blade tool, the tool wear is a change in the initial geometric shape of the cutting edge, including
the appearance of a wear hole on the front face and wear chamfers on the rear face, the increase of the cutting edge
curvature radius, etc. These changes disrupt the normal course of the cutting process: the cutting force and temperature
increase, vibrations occur in the system, and the quality of the processed surface deteriorates.
To assess the machinability of materials, various indicators of the cutting process are used; they include the quality
parameters of the processed surface, specific productivity, components of the cutting force, tool cutting coefficient, wear
and tools life, material removal rates [17, 18].
The question arises which of several indicators of the cutting process is considered the main criterion for machinability.
Choosing this criterion, the following should be considered: it should be generalized, i.e. be related in one way or
another with other indicators of the cutting process, and it must also have a physical basis for evaluating machinability.
The analysis of different machinability criteria indicates that the tools life gives a very clear idea of the deterioration of
machinability of various materials.
Due to the machinability deterioration, there is a tendency for cutting forces and tool wear to increase and for the
specific productivity, metal removal, cutting coefficient to decrease.
2.1 The mathematical model of the optimal material removal rate
Increasing parameters of the processing mode increase significantly the load on the edges of the cutting tool, which
leads to a decrease in the tool life. Having taken the optimum material removal rate Q0 as a basis of the influence of the
regime factor on the tool life, it is possible to simplify greatly the preparation of the dependence of the tool life on the
processing modes. The basis of this approach is that the life and performance of the cutting tool depend on the load on
the cutting edges, the quantity of the material to be processed and the speed it goes into chips.
A large number of studies show the relationship of the material removal rate with such process indicators as cutting
force, tool life and wear [19, 20].
The dependence of the cutting tool life T on the material removal rate Q is expressed as a power law, which is
commonly called the T-Q characteristic of the cutting process
T  CT / Q n , (1)
where Q is the material removal rate over the cutting tool life T, measured in mm3/min; СТ is the coefficient, which
depends on the processing conditions, min/(mm3/min); n is a degree indicator that shows the intensity of the tool life
decrease due to combinations of processing mode parameters. The feasibility study of the effectiveness of the use of
cutting tools, produced by various manufacturers, when machining surfaces of the part, makes it critical to know T-Q
characteristics of the cutting process for a specific cutting tool [21]. If the dependence of the T-Q characteristics of the
cutting process is known and the cutting tool life T is indicated, then using formula (1), one can determine the material
removal rate Q and assign a combination of controlled parameters of the processing mode to it. This characteristic
allows you to determine the health of the cutting tool in the entire range of changes in the recommended parameters of
the processing mode for each stage, and it can be used as an indicator of the cutting machinability of various materials.
The values of the T-Q characteristics constants (СТ and n), which are the basis for the economic evaluation of the
process efficiency and have not yet been defined for a large range of cutting tools from various manufacturers,
recommended for processing the same elementary surfaces on multi-operational CNC machines, can serve as a
workability criterion.
The T-Q characteristics of the cutting process include two unknown СТ and n, which should be determined for each
cutting tool. To determine them, systems of two equations are solved, containing different material removal rates Q and
the corresponding tool life T [22].
The material removal rate Q included in formula (1) depends on a combination of controlled parameters of the cutting
mode during processing of an elementary surface. The parameters of cutting modes recommended by official
publications5 when machining elementary surfaces are designed for the use of various cutting tools that have optimal
values of the geometric parameters of the cutting part. When assigning the parameters of the cutting conditions, the
type and dimensions of the cutting tool, the material of the cutting part of the tool, the type and stage of processing, the
material and condition of the workpiece, as well as the type and condition of technological equipment are taken into
account. The parameters of the cutting mode are usually set in the following sequence:
- cutting depth t: the maximum cutting depth, equal to the removed allowance or most of it, is assigned during
roughing or preliminary processing; when finishing, the depth is assigned depending on the requirements for
dimensional accuracy and roughness of the processed elementary surfaces;

- feed f: the maximum possible feed is assigned during roughing, taking into account the power of the main drive or
feed drive, the stiffness and strength of the elements of the system, the strength of the tool insert and other limiting
factors; during finishing, the feed is prescribed depending on the required accuracy and roughness of the treated
surfaces;
- the cutting speed V is calculated according to empirical (resistance) dependencies established for processing each
elementary surface, which have a general view:
CV
V   KV . (2)
T tx  f
m y
The values of the coefficient Cv and exponents (m, x, y) in these expressions are given in the reference tables for each
elementary surface. The coefficient KV characterizes the features of processing an elementary surface according to the
actual state of the components of the technological system and the material of the processing object, and is calculated
from the following expression:
KV  K M V  K SV  K TV ,
where КMv is a coefficient that takes into account the quality of the processed material, КSv is a coefficient that takes
into account the surface condition of the workpiece, КTv is a coefficient that takes into account the quality of the
material of the cutting tool and the features of its geometry. The calculated expressions for determining the components
of KV or their numerical values when processing elementary surfaces are given in the tables of the reference literature.
From expression (2) with KV = 1, the base (starting) value of the cutting speed is calculated.
A similar sequence of assignment of cutting mode parameters is defined by metalworking guidelines of manufacturers
of cutting tool manufacturers. The only difference is that the base (starting) value of the cutting speed is not calculated,
but is selected from the tables of metalworking manuals taking into account the material of a replaceable polyhedral
plate or a monolithic cutting tool, the shape of the plate and the type of chipbreaker, feed and cutting depth. The table
values of the starting cutting speed V15 correspond to the tools life of the cutting tool equal to 15 minutes when working
with cooling. Then the working cutting speed is calculated from the expression
V  V15  K V X  K VT  K VHB ,
where KVX, KVT, KVHB are the correction factors, respectively, for the condition of the machine and the surface of the
workpiece, the required tools life plate or monolithic cutting tool, the processed material and its hardness.
To determine the СT and n Т-Q characteristics constants of the cutting process, it is necessary to have a functional
dependence for calculating the starting cutting speed, which is similar in structure to formula (2), but with a converted
1
coefficient CV for the cutting mode parameters recommended by the manufacturer of the cutting tool (t, f, V15) with its
1
tool life of 15 minutes. The functional dependence for calculating the coefficient CV , taking into account expression
(2), will have the following form:
CV1  V15  15m  t x  f y ,
and the functional dependence for calculating the starting cutting speed, at constant t and f, for an arbitrary tool life T
takes the following form:
VT  V15  (15 T ) m ,
1
The coefficient CV for the cutting tool is calculated from the expressions of tool life dependencies for various cutting
methods5:
y
1 V15  T m  t x  f
for turning: Cv  ;
KV
1 V15  T m  f zy  t x  Bu  z p
for milling: Cv  ;
Dq  KV
1 V15  T m  f y
for drilling, tapping: Cv  ;
KV  Dq

1 V15  T m  f y  t x
for countersinking and deployment: Cv  ;
D q  KV
1 V15  T m  f y
for tapping with cutting inserts: Cv  .
KV  i x
Analytical dependences for calculating the material removal rate for various processing methods are given in [23].
The value of the optimal material removal rate Qо, which corresponds to the minimum cost, is determined from the
expression 3
Ctrw.
Qo  ( )1/n , (3)
(n  1)  (Ctrw.  tst /CT  St /CT )
where Сtrw - the tariff rate of the worker, taking into account overhead costs; tst - time spent on changing the cutting
tool; St - the cost of the cutting tool.
2.2 The mathematical model of the optimal cutting speed
By calculating the optimum material removal rate Qo of processing each elementary surface, it is possible to determine
the optimal cutting speed Vo, with the unchanged combinations of other parameters of the processing mode of
elementary surfaces, that correspond to the adopted tool life T. Calculated expressions for determining Vo will have the
following form:
Qo
for turning: Vo  m/min;
f o  to  103
Qo  π  D
for milling: Vo  m/min;
B  to  f zo  z  103
4  Qo
for drilling: Vo  m/min;
D  fo  103
4  D Qo
for countersinking and deployment: Vo  m/min;
D  Do 2  fo 103
2  i  Qo
when cutting metric threads with a plate: Vo  m/min;
f 2  103  cos(30o )
when tapping metric threads: 2Qo D m/min.
Vo 
π  4 π 
f 2  10 3  cos    D  f  cos  
6
   3 6
 
Having determined the combination of controlled processing mode parameters that provide the optimal material
removal rate Qо calculated by formula (3), it will be guaranteed that the processing efficiency of elementary surfaces
will be ensured with the required quality indicators.
2.3 The relationship of processing modes with the optimal material removal rate
Let us establish the functional dependences of the controlled parameters of the regime of different cutting methods for
cutting tools at an optimal material removal rate Qo, using the obtained analytical dependencies to calculate the
material removal rate [23].
The controlled parameters of the machining mode during turning and boring are: t - cutting depth, f - cutting tool feed.
The cutting speed V, according to [5], is determined from the following expression:
CV1
Vo  ,
T m  f y tx
in which, the values of exponents (m, x, y) are established from the tables in the reference literature.
The material removal rate during turning is determined from the expression:

CV1  f  t  103 CV1  103 1 x 1 y

Q  V  f  t  103   t  f .
Tm  f y tx Tm
Substituting the initial expression Q  Q0 for the recommended cutting tool, and converting it, we obtain a functional
dependence of the optimal parameters of the turning mode (to, So) at the optimum material removal speed
corresponding to the adopted tool life T, in the form:
Q0  T m
t01 x  f 01 y  . (4)
CV1  103
From this expression, sorting out the controlled parameters of the processes of turning and boring, in the recommended
ranges of their change for each stage of processing, the optimal combination of to and So is established.
Solving the obtained mathematical model (4), we present the graphic results of the solutions in the form of functional
dependences S=f(t) corresponding to the adopted tool life T = 15, 30, 45 min. (fig. 1).
Having performed similar transformations for other processing methods, we present the obtained functional
dependences of the optimal controlled parameters of the processing mode at the optimal material removal rate (table 1).
Based on the functional dependences of the controlled parameters of various processing methods on the optimum
material removal rate shown in Table 1, one of the many optimal combinations of controlled parameters of the
processing methods presented in the form of maps for the recommended cutting tool in tables 2 - 9 is calculated.
0,300
f о, mm/rev
0,250
Т=15 min
0,200
Т=30 min
Т=45 min
0,150
0,100
1,25 1,50 1,75 2,00 2,25 2,50
t о , mm
Figure 1 Taegu Tec DNMG 150608 PC TT8115 plate tool life map for external turning and end turning (40X steel)
Table 1: The dependence of the optimal controlled parameters of the processing methods mode on the optimal material
removal rate, corresponding to the accepted tool life.
Controlled
Processing method parameters of Functional dependences
processing
Q0  T m  f zy  z p  
1 x
f 0  t0  ,
CV1  103  D q 1  B1u
for milling f, t
Q0    D
V0 
B  t0  f 0  103
1 y4  T m  Q0
f0  ,
CV1  103 D q 1
for drilling f
4  Q0
V0 
D  f 0  10 3
for countersinking 1 y 4  Q0  T m
f, t f0  t x  ,
and deployment C  10  D q1  ( D  D0 ) 2
1
V
3

4  Q0  D
V0 
( D  D0 ) 2  f 0  10 3
x 1 2  Q0  T m
f 2 y  i  ,
when cutting metric CV1  103  cos(30 )
f, i
threads with a plate 2  Q0  i
V0 
f  103  cos(30 )
2
4 2 y 2  Q0  T m
(D   f 0  cos(30 ))  f 0  1 ,
when tapping metric 3 CV  10 3  D q 1  cos(30  )
f
threads 2  Q0  D
V0 
 4 
f 2  103  cos( )  ( D   f  cos( ))
6 3 6
Table 2: Map of the optimal parameters combination for external turning and turning of the end face with the
Taegu Tec DNMG 150608 PC TT8115 plate for a given plate tool life.
№ Parameter Т=15 minutes Т=30 minutes Т=45 minutes
1 tо, mm 1,25 1,50 1,75
2 fо, mm/rev 0,26 0,25 0,24
3 Vо, m/min 349,50 302,90 270,50
4 Qо, mm3/min 113600,00 113600,00 113600,00
Table 3: Map of the optimal parameters combination for boring with the Sandvik CNMG 120408 PM 4225 plate
for a given plate tool life.
1 tо, mm 1,00 1,75 2,00
2 fо, mm/rev 0,27 0,18 0,17
3 Vо, m/min 346,50 296,80 275,20
4 Qо, mm3/min 93500,00 93500,00 93500,00
Table 4: Map of the optimal parameters combination for grooving with the Sandvik N123H2-0400-0002-GF 1125
plate for a given plate tool life.
1 tо, mm 0,25 0,50 0,50
2 fо, mm/rev 0,18 0,10 0,11
3 Vо, m/min 181,40 159,30 143,94
4 Qо, mm3/min 8420,87 8420,87 8420,87
Table 5: Map of the optimal parameters combination for external threading with the Sandvik 266RG-
16MM01A200M 1125 insert for a given plate tool life.
1 f, mm/rev 2,00 2,00 2,00
2 i, number of passes 8,00 8,00 8,00
3 tо, mm 0,22 0,22 0,22
4 Vо, m/min 138,12 138,12 138,12
5 Qо, mm3/min 29903,00 29903,00 29903,00
Table 6: Map of the optimal parameters combination for milling the ledge with the Hanita 4777-16006 LT milling
cutter for a given tool life.
1 tо, mm 1,25 1,50 1,75
2 fо, mm/rev 0,22 0,25 0,27
3 Vо, m/min 147,58 107,17 86,79

4 Qо, mm3/min 13083,63 13083,63 13083,63

Table 7: Map of the optimal parameters combination for drilling with the Sumitomo SDP 1090 U5HAK PCX70
drill for a given drill tool life.
1 fо, mm/rev 0,13 0,21 0,28
2 Vо, m/min 130,87 82,44 62,91
3 Qо, mm3/min 48564,80 48564,80 48564,80
Table 8: Map of the optimal parameters combination for deployment with the Ost-Express SR50057-12.80 scan for
a given scan tool life.
1 tо, mm 0,10 0,10 0,10
2 fо, mm/rev 0,13 0,29 0,46
3 Vо, m/min 27,19 12,31 7,74
4 Qо, mm3/min 0,703 0,703 0,703
Table 9: Map of the optimal parameters combination for tapping with Vergnano M8x1.25 A70K HSSK TiN for a
given tap tool life.
1 f, mm/rev 1,25 1,25 1,25
2 Vо, m/min 13,99 13,99 13,99
4 Qо, mm3/min 7758,26 7758,26 7758,26
3. CONCLUSION
The developed methodology and maps of the optimal combination of parameters for the processing of elementary
surfaces for the adopted tool life of the cutting tool are normative guidance materials for technologists in the
development of technological processes for the manufacture of parts and programmers in the development of control
programs for multioperational CNC machines.
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AUTHORS
Valentin Svirschev, Doctor of Technical Sciences, Professor,Professor at the ITM Department since 1998. Research
area mechanical processing of materials.
Alexey Savlov, Candidate of Technics, Associate Professor at the ITM Department since 2020. Research area
mechanical processing of materials.
Stepan Tarasov, Candidate of Technics, Associate Professor at the ITM Department since 2015. Research area
mechanical processing of materials.

The Determination of The Optimal Combination of Processing Mode Parameters Based On The Machinability Criterion "Optimal Material Removal Rate"

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The Determination of The Optimal Combination of Processing Mode Parameters Based On The Machinability Criterion "Optimal Material Removal Rate"

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International Journal of Application or Innovation in Engineering & Management (IJAIEM)

Web Site: www.ijaiem.org Email: editor@ijaiem.org

The determination of the optimal combination

Volume 9, Issue 7, July 2020 Page 50

Volume 9, Issue 7, July 2020 Page 51

Volume 9, Issue 7, July 2020 Page 52

Volume 9, Issue 7, July 2020 Page 53

CV1  f  t  103 CV1  103 1 x 1 y

Volume 9, Issue 7, July 2020 Page 54

Volume 9, Issue 7, July 2020 Page 55

4 Qо, mm3/min 13083,63 13083,63 13083,63

Volume 9, Issue 7, July 2020 Page 56

Volume 9, Issue 7, July 2020 Page 57

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