Sensitivity of Shear Process in Metal Cutting to the Development of Residual Stress

Machining processes are widely used for producing a component by material removal. Material is removed in the form of chips through the action of the wedge-shaped cutting tool. As the tool proceeds, the material is first elastically deformed, and then plastically deformed. The mechanism of plastic deformation in metal is dislocation movement Typical machining processes include turning, milling, drilling, shaping and grinding. It is known that the chip formation process in metal cutting is quite unique in many ways [1]. First, the process is a localized, asymmetric deformation that takes place at very large strains and exceptionally high strain rates in a small deformation zone. Typical values for strains and strain rates range 2 to 5 and 104 to 109 per second, respectively. Second, it is relatively unconstrained in that the only external constraint is the length of contact between tool and chip on the rake face of the tool. On the rake face there may be seizure as well as sliding friction. Machining introduces a large amount of plastic deformation in the workpiece material and chip. This plastic strain is nonuniform, and therefore residual stresses are induced in the workpiece surface and subsurface throughout, and slight below, the depth of plastic deformation. Thus, residual stresses are often an undesirable but unavoidable by-product of machining

The relevance of outsourcing and leagile strategies in performance optimization of an integrated process planning and scheduling

Over the past few years growing global competition has forced the manufacturing industries to upgrade their old production strategies with the modern day approaches. As a result, recent interest has been developed towards finding an appropriate policy that could enable them to compete with others, and facilitate them to emerge as a market winner. Keeping in mind the abovementioned facts, in this paper the authors have proposed an integrated process planning and scheduling model inheriting the salient features of outsourcing, and leagile principles to compete in the existing market scenario. The paper also proposes a model based on leagile principles, where the integrated planning management has been practiced. In the present work a scheduling problem has been considered and overall minimization of makespan has been aimed. The paper shows the relevance of both the strategies in performance enhancement of the industries, in terms of their reduced makespan. The authors have also proposed a new hybrid Enhanced Swift Converging Simulated Annealing (ESCSA) algorithm, to solve the complex real-time scheduling problems. The proposed algorithm inherits the prominent features of the Genetic Algorithm (GA), Simulated Annealing (SA), and the Fuzzy Logic Controller (FLC). The ESCSA algorithm reduces the makespan significantly in less computational time and number of iterations. The efficacy of the proposed algorithm has been shown by comparing the results with GA, SA, Tabu, and hybrid Tabu-SA optimization methods