Integrated computer-aided optimal design and finite element analysis of a plain milling cutter

Abstract

AbstractThis paper presents the computer-aided integration of solid modelling, optimization, and finite element analysis. Interactive (three-dimensional) solid modelling is used in the development of relatively efficient and fast solutions to the many constraints and/or limitations encountered in the design process. The study also addresses the fatigue analysis using 3D finite element analysis on a workstation. Throughout the study, interactive 3D solid modelling is used in the development of a practical and economical design procedure. The research highlights the interactive and integrated nature of the design tasks. An optimal formulation of an automatic design algorithm is also carried out. The cost minimization objective function along with design constraints and behavior constraints are developed. The optimal design parameters thus obtained are tested for stresses at the tip of the tool and at the fillets. Interactive application of optimization, solid modelling, and finite element techniques produce the acceptable optimal design. The design methodology presented in this paper is general and generic in nature. This has been illustrated through an example of design of a plain milling cutter