A Novel Tool Geometry Approach for Process Optimization in CNC-Based SMEs

Computer Numerical Control (CNC) machining retains relevance for unerring performance and productivity amid the volatile automobile scenario. Small and Medium Enterprises (SMEs) face the dilemmas of tool wear, thermal instability, and non-graded machining methods, which form the increased operational cost and lesser output. Under the ambit of the study, a thrust formulation was offered as a solution to Shubham Industries, a CNC-based SME located in Aurangabad, India, engaged in automotive component manufacturing, for process optimization and tool life enhancement. The study revealed that tool wear was very rapid, chip evacuation was very poor, and excess heat was generated due to the use of non-standard cutting tool geometries. Taking into consideration process parameters like tool material, rake, and flank angles and concentration of coolant, a novel standardized tool was designed. That is, details for a cutting tool have been provided with a rake angle of 8° and flank angle of 28°, as well as a specially prepared fixture to allow for re-sharpening. These implementations were then done on the CNC machines in actual production environments. An increase in tool life of 35% was reported with a 40% reduction in thermal loads imparted during cutting procedures. The immediate monthly cost savings were INR 13,440, with the yearly cost savings above INR 1.6 lakhs. Dimensional accuracy and quality of surface finish have shown improvements as well, which are prime requirements in automotive manufacturing. With a better design for the fixture, the re-sharpening becomes easier, therefore further reducing both operator dependency and downtime. CNC machining provides a scalable and economical paradigm for SMEs in the automobile industry so that these companies can work on standardizing cutting tool geometries and, in turn, process parameters to increase productivity and guarantee uniform quality at lower manufacturing costs for lean and sustainable production systems.