Optimization of cutting parameters in milling based on tool wear model

Abstract

High accuracy and machining capability are the main requirements for metal cutting operations, and high cutting speed and feed rate increase machining accuracy and material removal rate, but lower tool life. In this paper, a tool wear life model is developed during milling and a method is proposed to determine the cutting parameters that maximize the tool wear life under certain metal removal rates. The tool wear model is constructed by a polynomial regression model using simulation data from Deform 3D and the cutting parameters are optimized using Matlab’s fmincon function. The proposed method is verified through cutting of high temperature alloy Ti6A14V and can be applied to determine cutting parameters that maximize tool life in machining various hard-working materials.