Integrated computer-aided optimal design and finite element analysis of a plain milling cutter (Q1900566)

The authors consider 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 three-dimensional finite element analysis on a workstation. Throughout the study, interactive three-dimensional solid modelling is used in the development of a practical and economical design procedure. The paper 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 behaviour constraints is developed. The optimal design parameters thus obtained are tested for stresses at the tip of the tool and at the fillets. The design methodology presented is general and generic in nature. This has been illustrated by an example of design of a plain milling cutter.