Optimization of cutting tool geometry based on flank wear – DoE, PSO and SAA approach

In this analysis, an attempt has been made to study the effects of included angle, hardness, rake angle, tool approach angle and nose radius of cutting inserts on flank wear with the surface roughness as constraint. The selected parameters are varied through three levels. A new parametric study without considering any kind of benchmark problems in this area is performed and methodology has been developed to analyze the effects of selected parameters on the flank wear of cutting insert. As per the L18 orthogonal array, the values of flank wear after machining are measured and recorded. The best levels of selected parameters for the minimization of flank wear are identified by using Taguchi’s Design of Experiments. A validation experiment is conducted with the identified best levels of parameters, and the corresponding flank wear is recorded. Also this analysis inter-relates the performances of design of experiments (DoE), regression analysis, particle swarm optimization and simulated annealing algorithm (SAA) to obtain the best possible solution. The result of this analysis identifies the optimal values of selected parameters for effective and efficient machining. The experimental, optimized and predicted values of flank wear are compared and correlated for all the test conditions.