Title: Milling optimisation of removal rate and accuracy with uncertainty: Part 1: parameter selection

Authors: Mohammad H. Kurdi, Tony L. Schmitz, Raphael T. Haftka, Brian P. Mann

Addresses: Mechanical and Aerospace Engineering Department, University of Florida, Gainesville, FL 32611, USA. ' Mechanical and Aerospace Engineering Department, University of Florida, Gainesville, FL 32611, USA. ' Mechanical and Aerospace Engineering Department, University of Florida, Gainesville, FL 32611, USA. ' Mechanical and Aerospace Engineering Department, University of Missouri, Columbia, MO 65211, USA

Abstract: Successful implementation of milling requires the selection of appropriate operating parameters. In this paper a semi-analytical modelling approach and multi-objective optimisation are used to select optimum spindle speed and axial depth. The trade-off curve of removal rate and surface location error is calculated. Some degree of robustness is achieved by calculating the surface location error as a moving average over an interval of spindle speeds. The stability boundary and a selected design are compared to experimental results. The results illustrate the need to be concerned with the robustness of the optimal designs. This is addressed in Part 2 of the paper.

Keywords: milling optimisation; multi-objective optimisation; sensitivity; Pareto; uncertainty; correlation; stability; parameter selection; modelling; spindle speed; axial depth; material removal rate; MRR; surface location error; optimal design.

DOI: 10.1504/IJMPT.2009.025209

International Journal of Materials and Product Technology, 2009 Vol.35 No.1/2, pp.3 - 25

Available online: 16 May 2009 *

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