Design/Evaluation of A Methodology For
Performance Optimization Of Indexable
Carbide Inserts
By
Fritz Alum, Yah
Degree Project
Mech. Engineering
DEGREE PROJECT
Masters Thesis
Mechanical Engineering
Degree Program Reg number Extent
Product and Production Development, 30ECTS E 3835 M 6 months
Name of student Year-Month-Day
Fritz Alum Yah 2010-01-17
Supervisor Examiner
Bengt Lofgren Dr. Roger Johansson
Company/Department Supervisor at the Company/Department
SECO Tools AB Mats Jonsson
Title
Design/Evaluation of A Methodology For Performance Optimization Of Indexable Carbide Inserts
Keywords
Factorial design, Regression model, Center point, Response surface, Material model
Summary
In this project, two broad facets in the design of a methodology for performance optimization of indexable carbide inserts were examined. They were physical destructive testing and software simulation.
For the physical testing, statistical research techniques were used for the design of the methodology. A five step method which began with Problem definition, through System identification, Statistical model formation, Data collection and Statistical analyses and results was elaborated upon in depth. Set-up and execution of an experiment with a compression machine together with roadblocks and possible solution to curb road blocks to quality data collection were examined. 2k factorial design was illustrated and recommended for process improvement. Instances of first-order and second-order response surface analyses were encountered. In the case of curvature, test for curvature significance with center point analysis was recommended. Process optimization with method of steepest ascent and central composite design or process robustness studies of response surface analyses were also recommended.
Abstract
In this project, two broad facets in the design of a methodology for performance optimization of indexable carbide inserts were examined. They were physical destructive testing and software simulation.
For the physical testing, statistical research techniques were used for the design of the methodology. A five step method which began with Problem definition, through System identification, Statistical model formation, Data collection and Statistical analyses and results was indepthly elaborated upon. Set-up and execution of an experiment with a compression machine together with roadblocks and possible solution to curb road blocks to quality data collection were examined. 2k factorial design was illustrated and recommended for process improvement. Instances of first-order and second-order response surface analyses were encountered. In the case of curvature, test for curvature significance with center point analysis was recommended. Process optimization with method of steepest ascent and central composite design or process robustness studies of response surface analyses were also recommended.
For the simulation test, AdvantEdge program was identified as the most used software for tool development. Challenges to the efficient application of this software were identified and possible solutions proposed. In conclusion, software simulation and physical testing were recommended to meet the objective of the project.
Key words:
Dedication
Table of Contents Abstract………...………1 Dedication……….………..………2 Table of contents……….………3 1 Introduction…….………..……….…………4 1.1 Metal Cutting………… ………...……….………...4 1.2 Problem area……… .……….….…….………….5 1.3 Tool wear ………..…………9
1.4 About Finite element method………9
1.5 Objective………9
1.6 Delimitation………...…………9
1.7 Approach………..……….9
2 Theory………11
2.1 Fundamental steps in statistics……….………...11
2.2 Blocking………..20
2.3 Screening versus optimization……….21
2.4 Analysis with finite element method……….. 21
3 Method……….………23
3.1 Physical test……….……….23
3.2 Finite element method of analysis……….………..26
4 Implementation……… ………27
4.1 The compression machine………...……27
5 Analyses, Part I, Section A & B, ………..……….………..….31
5-A1 Analyses of strength tests without heat…...………32
5-A2 Deflection analyses for tests without heat……….…..49
5-B1 Analyses of strength tests with heat..………..79
5-B2 Deflection analyses for tests with heat………..……115
6 Results……….………...125
6.1 Insert strength……….………125
6.2 Insert deflection……….……….135
7 Finite Element Method………..……137
8 Discussion………...…..140 8.1 Physical test………...……140 8.2 Simulation test……….………...…………143 8.3 Evaluation of methodology……….………...143 9 Conclusion……….………144 References ………..145
Appendix 1: Tables of data collected……….………… 147
Appendix 2: Manual calculation with 2k Factorial design………..168
