The paper presents a decision analytic framework for optimal machining parameter selection in titanium milling, considering uncertainty in tool life and stability. An influence diagram showing the decision situation, the corresponding uncertainties and the value was developed. The objective was to select optimum machining parameters to minimize machining cost while considering uncertainty in tool life and stability. The uncertainties were characterized using a probability distribution taking into account all available information. The cost associated with tool failure and unstable cutting conditions was incorporated in the cost formulation. A process probability tree showing the uncertainties and the corresponding costs was constructed. The optimal machining parameters were selected which minimize the expected machining cost. Results show a 90% reduction in machining cost as compared to manufacturer recommended parameters. A discussion section regarding inference and experimental design is included.

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