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.
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.
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