The aim of this paper was focused on research in order to improve the manufacturing of aluminium alloy thin-walled components through the optimization of milling process parameters. The methodology for optimization of milling parameters is developed and presented. The influence of the tool path strategy, wall thickness and feed rate on the machining time, dimensional accuracy deviation, shape and position accuracy deviation, and surface roughness in the case of line-type thin-walled parts machining were analysed. Based on the analysis of experimental results, the corresponding empirical models of responses were identified. Optimization of results was conducted using response surface methodology. Verification of optimization results was executed using two additional experiments. The results from experimental verification show a satisfactory matching with calculated optimal values. The basic scientific contribution of the paper relates to the development of a methodology for optimization of machining parameters for milling of thinwalled structures of aluminium alloy using an ANOVA method, Central Composite Design experiment and empirical modelling. Practical implications are related to the correct selection of the tool path strategy and feed rate value for machining of thin-walled aluminium components in order to achieve the required output techno-economic effects.

Process planning is one of the most difficult tasks in product development caused by the large number of technical, technological, economic, environmental and other criteria. Accordingly, the selection of manufacturing processes is a complex multi-criteria decision making problem since it considers a number of possible alternative manufacturing processes in addition to a large number of specified criteria. This paper represents the computer-aided methodology for the multi-criteria evaluation and selection of manufacturing processes at the stage of conceptual process planning. The developed methodology is primarily focused on the mapping of product design and manufacturing requirements. Manufacturing processes that fail to meet the given conditions on the basis of 10 criteria such as materials, production volume, productivity, dimensional accuracy, surface finish, etc., are eliminated according to the developed rules. Then, the multi-criteria evaluation and ranking of manufacturing processes is performed based on 5 criteria: manufacturing cycle time, process flexibility, material utilization, quality and operating costs. Based on this methodology, a system is developed for the multi-criteria selection of manufacturing processes, whose implementation is presented in the case of the hip joint endoprosthesis.

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Thin-walled parts made of aluminum alloy are mostly used as structural elements in the aerospace, automobile, and military industries due to good homogeneity, corrosion resistance, and the excellent ratio between mechanical properties and mass. Manufacturing of these parts is mainly performed by removing a large volume of material, so it is necessary to choose quality machining parameters that will achieve high productivity and satisfactory quality and accuracy of machining. Using the Taguchi methodology, an experimental plan is created and realized. Based on its results and comparative analysis of multi-criteria decision making (MCDM) methods, optimal levels of machining parameters in high-speed milling of thin-walled parts made of aluminum alloy Al7075 are selected. The varying input parameters are wall thickness, cutting parameters, and tool path strategies. The output parameters are productivity, surface quality, dimensional accuracy, the accuracy of forms and surface position, representing the optimization criteria. Selection of the optimal machining parameter levels and their ranking is realized using 14 MCDM methods. Afterward, the obtained results are compared using correlation analysis. At the output, integrative decisions were made on selecting the optimal level and rank of alternative levels of machining parameters.

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