Selection of Optimum Cutting Speed In End Milling Process Using Fuzzy Logic

Abstract

The machining process shows ambiguous behavior and often cannot be linearly extrapolated in a wide range. It cannot be modeled effectively using theories and equations. The classical method for selection of machining parameters, such as cutting speed  is based on data from machining hand books for machining parameters or on the experience of the operator or CNC programmer. The parameters chosen in most situations are highly conservative to protect over- matching errors from tool failures, such as deflection, breakage, etc.  In this paper,  a model to find the optimum cutting speed for end milling operation was built using Fuzzy Logic, this model is user-friendly and compatible with the automation concept of a flexible and computer integrated manufacturing systems. It allows the operator, even unskilled, to find the optimal cutting speed for an efficient machining process that can lead to an improvement of product quality, increase production rates and thus reducing product cost and total manufacturing costs. The developed fuzzy logic model showed a good prediction to select the optimum cutting speed , with a mean absolute error of around 4.5% from the optimum machining parameters in the Machining Data Handbook.

Keywords: Fuzzy Logic, End Milling Process, CNC, FL, Optimum Cutting Speed Selection.