INTEGRATED COMPUTER-AIDED OPTIMAL-DESIGN AND FINITE-ELEMENT ANALYSIS OF A PLAIN MILLING CUTTER

This paper presents the computer-aided integration of solid modelling, optimization, and finite element analysis. Interactive (three-dimensi onal) solid modelling is used in the development of relatively efficie nt and fast solutions to the many constraints and/or limitations encou ntered in the design process. The study also addresses the fatigue ana lysis using 3D finite element analysis on a workstation. Throughout th e study, interactive 3D solid modelling is used in the development of a practical and economical design procedure. The research highlights t he inter active 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 thu s obtained are tested for stresses at the tip of the tool and at the f illets. Interactive application of optimization, solid modelling, and finite element techniques produce the acceptable optimal design. The d esign methodology presented in this paper is general and generic in na ture. This has been illustrated through an example of design of a plai n milling cutter.