Comprehensive process planning of contour turning operations

This paper presents a model-based process planning methodology for contour turning operations. Its strength lies in its ability to simulate process performance through the use of comprehensive mechanistic cutting process models that allows the planner to deal more realistically with the parameter selection problem. The methodology presented herein allows the planner to examine the issues of variable cutting forces, tool interference, and process stability along the cuffing path of a complex contour turning situation. The parameter selection process includes the selection of cutting conditions and tool geometry, subject to a set of pre-specified performance requirements, including the consideration of the groove tool and tool wear. The stability line chart for contour turning stability analysis is introduced. A comprehensive case study is conducted based on the machining of an automobile wheel rim contour.