Strategic Design Optimization of Cutting Tools for Enhanced Manufacturing Efficiency

The efficient utilization of manufacturing technology with respect to cutting tool design for the intended improvement of its structural characteristics is deemed critical. This study uses Finite Element Analysis (FEA) and the response surface approach to determine the effect of the design parameters of the cutting tool on its structural performance. The ANSYS simulation package is applied to capture valuable information from the explicit dynamic analysis with the help of which the critical stress zones and the chipping zones are obtained. The Box-Behnken optimization is used for the optimization of the Design of Experiments (DOE) and response surface which helps in deciding the design parameters that yield the best results. To critically evaluate the findings of this study, perceptions of 2D linearized curves and 3D response surface plots show that the base length has a positive impact on equivalent-stress and equivalent-elastic-strain while total deformation is most affected by the base angle. As evident from the findings of this study, more attention needs to be paid to the relationship between the design characteristics of cutting tools and their structural behaviors. Thus, it is possible to improve the tool performance, decrease the wear, and achieve the effective manufacturing costs. This research makes a contribution to the development of knowledge in the area of Cutting tools design and optimization and provides suggestions for enhancing technical processes and decreasing production expenses.