Analysis and optimization of cutter geometric parameters for surface integrity in milling titanium alloy using a modified grey–Taguchi method

Abstract

Surface integrity determines the performance and quality of the end product. It often needs to change the input parameters, such as cutting parameter, cutting tool geometry and material, and tool coating, to obtain the best machining surface integrity. This article presents and demonstrates the effectiveness for the multi-objective optimization of cutter geometric parameters for surface integrity of milling Ti-5Al-5Mo-5V-1Cr-1Fe titanium alloy via grey relational analysis coupled with the Taguchi method, entropy weight method, and analytic hierarchy process. The main influence factors are chosen as radial rake angle, primary radial relief angle, and helix angle, while surface roughness and residual stress are taken as performance characteristics. Based on the Taguchi method, an L16 (43) orthogonal array is chosen for the experiments. The effect of cutter geometric parameters on surface roughness and residual stress is analysed by signal-to-noise ratio. Then, the multiple objectives optimization problem is successfully converted to a single-objective optimization of grey relational grade with the grey relational analysis. The weight coefficient for grey relational grade is determined by entropy weight method integrated with analytic hierarchy process. The results show that the order of importance for controllable factor to the milling surface integrity, in sequence, is radial rake angle, primary radial relief angle, and helix angle. The validation experiment verifies that the proposed optimization method has the ability to find out the optimal geometric parameters in terms of milling surface integrity.

Effects of process combinations of milling, grinding, and polishing on the surface integrity and fatigue life of GH4169 components

“…The rake angle of cutting tools has a critical influence on residual stress. 25 The cutter with a more effective negative rake angle and higher thermal conductivity generate more compressive residual stress. 26…”

“…The rake angle of cutting tools has a critical influence on residual stress. 25 The cutter with a more effective negative rake angle and higher thermal conductivity generate more compressive residual stress. 26 For the M/MP/MH group, as shown in Figure 9(a), polishing completely removes the tensile stress of the sample M. The residual stress of sample MP is -834 MPa at the surface and monotonically decreases to 0 MPa at a depth of 80 mm.…”

Reliability-based Interval Optimization for the Disc-Mill Cutter Machining TC17 Blisk-Tunnel

“…Abbasi et al investigated the influence of changing the rake angle of the PCD insert on cutting forces, tool-chip interface temperature, and tool stresses and compared the results with a TiAIN coated carbide inserted end mill utilizing FEM. The result showed that the tool rake angle has significant influence and reveals a difference in the performance for the two kind of inserts [5]. Other researchers have analyzed tool wear mechanisms of machining titanium alloys.…”

Optimal selection of operating parameters in end milling of Al-6061 work materials using multi-objective approach

“…Ratnam et al (2016) studied the turn-milling process in tangential and orthogonal directions to minimize the surface roughness of extruded brass material. Several recent works focussed on the optimal machining parameters for multi-pass milling operations by considering the statistical and artificial intelligent techniques (Wang et al 2005;Sukumar et al 2014;Venkata Rao and Pawar 2010;Das et al 2016;Ren et al 2016). The efficiency of a neural network model was estimated by conducting the numerical simulations and experiments.…”