A new variational approach is presented for the MCDDSH process that leads to the optimal values of switching of machining cycles and feed rate. The problem is formulated as a nonclassical variational problem that best models the dynamics and control of a MCDDSH machine. Twist drills are used in the MCDDSH process considered here. All the control parameters like cutting forces, external disturbances, output quality, etc. are considered. Physical realization of the optimal strategy is achieved by taking into account the stochastic variation of system parameters. Control algorithms that yield maximum productivity are developed. Also investigated are the set of machining process states for the MCDDSH process and the specification of optimal switching positions of the machining cycles. These correspond to the appropriate optimal feed-rate that yields the best result.

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