Redução de custos em ferramenta de corte a partir de análise de experimentos: um estudo de caso aplicado à indústria automotiva

Abstract

The paper presents a case study with the application of statistical tool of design of experiments (DOE) in the crankshaft machining process, in order to reduce by 50% the machining costs of a turning operation. To reach this goal, a market research was carried out with the new machining technologies available for this application, as the current tool has a high added cost. In addition, several tests were carried out with the alteration of cutting parameters such as forward speed and motor rotation in order to obtain the best combination between these factors, resulting in less wear on the cutting edge and longer tool life. Initial test results and optimizations were analyzed using Minitab software. As a result, there was a reduction of 83% in the machining cost per part, exceeding the initial expectations of the project, in addition to maintaining the cycle time of this operation, which was one of the main problems to be faced due to the parameter and class changes of the insert. It was concluded that motor rotation has the greatest influence on insert wear, followed by forward speed, which is also significantly influential. The presence or absence of chip breaking in carbide inserts does not interfere with wear.