Service Communautaire d'Information sur la Recherche et le Développement - CORDIS

Quality assurance and reduction of lead time for cutting operations

A project was created to provide the process planner of a small or medium sized enterprise with a tool that can support him in the selection of methods, cutting tools and conditions for finishing operations. The results were as follows:
knowledge was acquired on parameters that influence quality, lead time, and typical values for obtainable quality parameters;
knowledge was acquired on the performance of different sorts of tools in finishing operations;
specific test procedures for the measurement of quality and for the assessment of method and tool selection were developed;
a method for the theoretical evaluation of roughness for comparative studies was established;
insight into the influence of dispersion within a batch of inserts was gained;
improved knowledge on the effects of predrilling on the final quality was acquired;
a new software for the calculation of cutting conditions was elaborated;
extensive tests were executed with the newest tools;
the relations between superficial residual tresses and machining conditions in aluminium were elaborated, and introduced in machining models;
test procedures for stability, capability and accuracy for machine tools were developed that can be applied by machine shops. A prototype planning system was developed to document the results in a structured way, validate end results and communicate the results to industry. The prototype is distinct from other feature based process planning systems in that it can explain its decisions with respect to method and tool selection. Texts are associated with selection rules describing test results. The knowledge generated can be used by companies which use cutting processes:
to improve the quality of their products;
to decrease manufacturing costs. This sort of knowledge can be used in books, training sessions, software for process planning, and also for computer aided design/manufacture systems. The model describing the relation between cutting parameters and residual stresses will improve the quality of the manufacturing process of vital parts in the Aerospace industry.