Design optimization of a chip breaker

Design Requirements
  • Minimize length of 2nd order bending torque
  • Satisfy 2nd order bending torque magnitude condition
  • Minimize maximum force asserted to the chip
Design Problem Formulation
  • Design variables  (7)
    Upper roller radius variation
    Lower roller radius variation
    Clearance length
    Upper belt thickness variation
    Lower belt thickness variation
    Entering angle
    Exit angle
  • Objective (2)
    Minimize length of 2nd order bending torque
    Minimize maximum force applied to the chip
  • Constraints (1)
    Satisfy 2nd order bending torque magnitude condition
Simulation and Design Software
  • Simulation : DAFUL, Matlab
  • Design : PIAnO
Design Optimization Process
  1. Establish automation and analyze design problem
  2. Perform design optimization using an optimizer
Optimization Result
  • 2nd order bending torque length reduced by 25.9% and maximum force applied to the chip reduced by 23.5% while satisfying all constraints