A. Javali, JNNCE, Shimoga, India,, SHIMOGA, India; D. S. Ramakrishna, JNNCE, SHIMOGA, India

Summary: DESIGN OPTIMIZATION OF TIPPED MILING CUTTRES FOR HIGH PERFORMANCE CUTTING OF ALUMINUM ALLOYS J.Ashoka1, Dr.D.S.Ramakrishna2, 1Doctoral student & Assistant professor in Industrial & Production Engineering. J.N.N. College of Engineering, Shimoga-India. ashjavali@yahoo.com 2Professor in Mechanical Engineering. J.N.N. College of Engineering, Shimoga-India. (Affiliated to Visveswaraiah Technological University, Belgaum –India) ABSTRACT This paper deals with the mathematical modeling and optimization of design of tipped milling cutters for high performance machining of Aluminum alloys. With the advent of high-speed computers and affordability, optimization algorithms are becoming increasingly popular. In any mechanical engineering design task, the purpose is to either minimize tool cost or to maximize tool life or component life. In the present day context, proprietary designs are becoming common, as they are tailor made to application specific. Use of interchangeable cutters, which are manufactured as per the I.S.O standards are restricted to general purpose milling with medium performance. Now a days milling of silicon-aluminum alloys with high Metal Removal Rate is becoming common practice and posing challenges for the tool design engineer. Aluminum alloys are lighter in weight and posses good heat transfer property. Hence these products find their place in aircrafts and automotives. Possibly Aluminum alloys may be the future material. Milling cutters are important tools in machining process. The finish obtainable in a machining process largely depends on the quality of the cutter. The process of metal cutting being complex depends on a number of design and process parameters. As these parameters are numerous, deciding about the criticality of a particular parameter over other parameters and studying the effect of each of such parameters on overall functioning of the cutting tool is very difficult. As the design space is large, the conventional method of modeling by making assumption may leave out important parameters. For optimally designing a cutting tool, all the parameters, which have significant role in design and performance, have to be brought into modeling. During the present work, it is aimed to design and develop a mathematical model for the design of milling cutter. Optimal and post optimal solutions are then obtained. Milling cutters are most important tools in metal cutting and machine tool industry. The design cycle of such cutters incorporate the following · Selection of tool material. · Fixing the complex geometry and tooth profile. · Design of different angles of the cutter. · Determining the load acting on the cutter. · Optimizing the design. But in this present day competitive world, the market demand for a good quality-cutting tool is very high. Also the needs of industry keep on changing rapidly. Designs may be made with the help of CAD techniques, but such designs are only feasible designs. Hence the proprietary design are to be made, and current research work take care of the following · To mathematically model the proprietary design problem. · To impose objectives on the model. · To impose manufacturing and design constraints on the model. · To establish optimal solution for the model. · To search for post optimal solutions which further improves design task Keywords: optimization, post-optimal solution, tooth-profile, design parameters.