Optimization method applied to hard turning of steel at the shop floor using maximum efficiency interval methodology to determine the cutting speed

Resumen

The main objective of this study is to propose a methodology to optimise the cutting processes when turning DIN 19MnCr5 G hardened steel. The method is based on Maximum Efficiency Interval (MEI), which considers the major process constraints involved. This enables the determination of the cutting conditions to be used at the shop floor. The MEI of the cutting speed, is determined mathematically, which is used as the bench mark value employed in the production process, of a serial production line for vehicle power transmission components. Polycrystalline Cubic Boron Nitride (PCBN) tools were used for the machining trials and tool life and tool wear mechanisms were evaluated. The results calculated by a mathematical model were in agreement with the experimental results. The use of this methodology could drastically reduce the machining costs at the shop floor.