Improved tools and ongoing research of machining increase continuously the cost-effectiveness of the process. The focus of development lies in the optimisation of tool geometry and the use of new, respectively concerning coating, in common cutting materials. This approaches are usually associated with considerable additional cost and, if seen individually, allow only a minor competitive advantage for producers.
In this paper originates from a market with state of the art tools and concentrates on the optimisation of the machining process. It is assumed, that with already developed tools better characteristics regarding wear and productivity could be achieved as common in current applications. This means, the profitability of process can be improved significantly on the basis of fundamental research of cutting parameters. The objective is to find an alternative to expensive coating- and material developments.
The economical importance of a continuous increase in productivity of the machining process is clearly evident when considering that the machining process covers the major part of industrial production. Activities in development as well as innovations within this field of manufacturing engineering will contribute to a great extent to ensure the competitiveness of industrial production in high-wage economies in the future.
The determination of cutting data in machining technology is largely based on empirical means. Theoretical models have brought merely minor benefit till now. The complexity of machining technology prevented a successful derivation of cutting data from results of common model calculation.
The present paper, which was conducted within the scope of a study of the University of Applied Sciences Upper Austria, presents a novel theoretical method. This method enables a practical description of the machining process and consequently to calculate the optimal cutting data.
Cutting tests with milling tools on two different steels showed the beneficial interaction of theoretical calculation and ideal practical machining. It was verified, that the cutting parameters derived from the model, significantly reduce the wear of tools and cut the imputed costs of processing up to 71%.
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Productivity progress in machining technology demonstrated by advanced theoretical methods in a study conducted by the Upper Austria University of Applied Sciences.