Development of hybrid predictive models and optimization techniques for machining operations

This paper presents a summary of recent developments in modeling and optimization of machining processes, focusing on turning and milling operations. With a brief analysis of past research on predictive modeling, the paper presents the analytical, numerical and empirical modeling efforts for 2D and 3D chip formation covering the development of a universal slip-line model, a comprehensive finite element model, and integrated hybrid models. This includes a newly developed equivalent toolface (ET) model and new tool-life relationships developed for machining with complex grooved tools. At the end, a performance-based machining optimization method developed for predicting optimum cutting conditions and cutting tool selection is presented. The paper also highlights the need for considering a machining systems approach to include the integrated effects of workpiece, cutting tool and machine tool.