Multiple performance characteristics optimization in end milling of thin-walled parts using desirability function

Abstract

With the development of high-performance CNC machine tools, milling has been established as one of the main means of machining thin-walled parts. Thus, the selection of process parameters for milling operations is an important issue in end milling of thin-walled parts to assure product quality and increase productivity. The current study explores three machining parameters, namely wall thickness, feed, and machining strategies, that influence dimensional and form errors, surface roughness, and machining time milling of 7075-T6 aluminum alloy thin-walled parts. The effects of machining parameters on each of the response variables were analyzed using graphs of the main effects and three-dimensional surface plots. Analysis of the results show that the most influential factor for wall thickness deviation, dimensions deviation, perpendicularity deviation, flatness deviation, surface roughness of inner walls, surface roughness of outer walls, and surface roughness of reference plane was machining strategy, while feed is the most influential parameter affecting the machined time, followed by the machining strategy. The desirability concept has been used for simultaneous optimization in terms of machining parameters of the thin-walled parts machining process. Finally, a confirmation test with the optimal parameter settings was carried out to validate the results.

Optimization algorithm for deep hole milling parameters of nickel-based alloys based on deep learning

“…In equation (2), Y is the qualified parameter roughness value for deep hole milling of nickel based alloy. It can be seen from the above formula that if the roughness of the part is lower than the roughness of the qualified parameter in the deep hole milling of nickel base alloy, then the parameter is proved qualified parameter, and the lower the roughness of the part is better; otherwise, the parameter is proved unqualified parameter.…”

“…In order to improve the milling effect, more and more experts and scholars have conducted in-depth research on the optimization of milling parameters. For example, a multiperformance feature optimization algorithm for thin-wall parts end milling was designed by Cica D et al The three machining parameters affecting the size and shape error, surface roughness and machining time milling of 7075-T6 aluminum alloy are discussed, and the influence of machining parameters on each response variable is analyzed using the main influence map and 3 D surface map [2]; A multi-objective optimization method for ultra-high strength steel AF1410 milling parameters based on the NSGA-II method was designed by XuJ et al The effect of milling parameters on milling force and surface roughness was investigated by analysis of variance, and a prediction model was established. Based on the non-dominant sequencing genetic algorithm II (NSGA-II), the milling force, surface roughness and material removal rate are optimized to achieve the multi-objective optimization of milling parameters [3]; In addition, Jackson A M et al designed a method of Ti6Al4V alloy end surface milling process parameters using gray correlation analysis algorithm.…”

Application of image processing technology based on field programmable gate array in mechanical part inspection

“…Cica's team proposed a milling based processing strategy for the wall thickness and feed rate of thinwalled parts to address the issue of the impact of process parameter selection on the quality of processed products. This strategy can synchronously optimize the machining parameters of thin-walled parts during the machining process (Cica et al, 2020). Yang et al proposed a new process control method to improve the reusability of polyamide 12 powder in response to the high economic losses and environmental friendliness of selective laser sintering additive manufacturing of complex parts.…”

Experimental Analysis and Optimization of Thin-Walled Tubular Parts Milling

“…1. Thin-walled structure deformation [3] The action of a relatively higher cutting force on the thin and high structure wall, leads to a large deviation of dimensions and shapes due to elastic and plastic deformations of the thin walls of the structure [6]. The deviation of the dimensions of the cylindrical thinwalled structure is specific, and is reflected in the changes in wall thickness in vertical direction, and deviations in terms of circularity and cylindricality.…”