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Corresponding Author

Rania Mostafa

Subject Area

Production Engineering and Mechanical Design

Article Type

Original Study

Abstract

The study of shape optimization techniques in structural products helps in reducing mechanical stresses and vibrations in related mechanical elements, such as cam follower mechanisms. This, in turn, has a positive impact on cost savings in the manufacturing process and enhances production quality and reliability. The point of view in this research depends on the idea of minimizing the total production cost while ensuring good functional performance of the cam profile during the shape-manufacturing optimization problem-solving process. The investigation of the impact of changing the motion type of a cam, such as Uniform Velocity Motion (UVM) and Simple Harmonic Motion (SHM), on the profile shape, manufacturing costs, and cam stresses is studied. The design variables of the optimization problem include the shape design variables (coordinates of B-spline control points) and manufacturing design variables (cutting parameters such as cutting speed, tool diameter, and feed rate). These variables are optimized by applying an integration of MATLAB 2021a and ANSYS 20. The problem solvers used are the interior point method (IPM) and the sequential quadratic programming (SQP) method. The minimum production cost is found, and an optimum shape of the cam profile is achieved when the cutting speed is 30 m/min, the feed rate is 0.17 mm/flute, and the cutter diameter is 25.4 mm. The best reduction in total cost while using the SHM motion type is about 32.74%, and the reduction in stress is about 9.44% (return motion) using the IPM algorithm after 40 iterations.

Keywords

Shape optimization. Manufacturing Cost Optimization. B-spline. Cam profile. Cam Mechanism.

Creative Commons License

Creative Commons Attribution 4.0 License
This work is licensed under a Creative Commons Attribution 4.0 License.

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