An intelligent approach for high material removal rate machining

Abstract

Machining is one of the most important manufacturing processes. Material removal rate (MRR) is a crucial issue in machining, but it is limited by machining stability lobe which depends on cutting dynamics. This chapter investigates an intelligent approach for increasing MRR. The approach increases the MRR by identifying the stability limit rather than constructing the whole stability lobe. Experiments are conducted using a machining center by machining the standard ISO test model with three typical materials: the aluminum alloy, the brass, and the SKD11 molding alloy. The results show that the average MRR for machining each material is increased to 281, 280, and 141 %, respectively. The merit of this approach is to reach high MRR by identifying chatter frequency without exhaustively finding the detailed stability lobes. © 2013 Springer Science+Business Media New York.