Decision system supporting optimization of machining strategy

An engine case is susceptible to significant deformation during machining, which causes cutting forces to vary and leads to quality issues. Those issues can be prevented if machining parameters are adjusted during machining strategy optimization in order to stabilize the cutting forces. The prevention of quality issues adds significant burden to costs and usually causes the reduction of machining efficiency. Therefore, the various costs of quality improvement and efficiency reduction must be examined prior to strategy optimization. The decision support system (I-DSS) developed as research a contribution of this paper allows to conduct such examination and to determine the guidelines for the two stages of strategy optimization. Those guidelines provide assurance that the variation of cutting forces will not exceed the required limits and the minimum level of efficiency will also be achieved. The system is illustrated using a real case study, at the conclusion of which the following two research questions are answered: (1) What is the impact of machining strategy optimization on milling and turning of an engine case made of Inconell 718, and (2) which approach to machining strategy optimization balances the quality and efficiency at the desired level of the overall costs.