Multi-Objective Parameter Optimization for Disc Milling Process of Titanium Alloy Blisk Channels

Abstract

The blisk has been widely used in modern high performance aero-engines of high thrust-weight ratio. Disc milling process provides a reliable way to improve the efficiency of the blisk milling. The process parameters of disc milling have crucial effects on the milling efficiency and physical property of blisk. In this paper, material removal rate, cutter life and thickness of residual stress layer are regarded as optimization targets the key process parameters such as spindle speed, cutting depth and feed speed are optimized. Based on the grey relational analysis, the multi-objective optimization problem is transformed into a single objective optimization problem. At the same time, the problem of non-symmetry influence of key process parameters on optimization targets can be solved. And the influence weight of material removal rate, cutter life and thickness of residual stress layer on the grey relational grade (GRG) are calculated according to principal component analysis. The second order prediction model of GRA is developed by response surface method. On the basis of verifying the accuracy of the model, the influence mechanism of the process parameters coupling on the gray correlation degree is analyzed the optimal process parameter combination is obtained as spindle speed with 81.92 rpm, cutting depth with 5.88 mm and feed rate with 66.0823 mm/min. The experimental research show that the optimal process parameter combination can effectively improve the material removal rate and cutter life and reduce the thickness of residual stress layer.

Prediction of surface roughness and optimization of process parameters for efficient cutting of aluminum alloy

“…For example, Chen et al 27 proposed an efficient processing scheme of hardened steel sealing groove, designed the experiment by using the orthogonal test method, obtained the influence law of different process parameters on the tool life, and optimized the turning process parameters according to the analysis results, but this is only an optimization with the single objective of ensuring the tool life, which does not fully reflect the high-efficiency cutting machinability; Li et al 28 established an energy-saving optimization model of NC turning batch processing process parameters considering tool wear to minimize the total energy consumption and completion time of batch processing and take the process parameters under different tool wear conditions as optimization variables and used multi-objective simulated annealing algorithm for optimization solution, mainly focusing on the field of efficient turning processing. Li et al 29 used the response surface method to design the insert milling experiment, established the empirical model of cutting force, took the cutting force and material removal rate as the goal, and used the NSGA-II algorithm to carry out multi-objective optimization to obtain the Pareto optimal solution, to realize the efficient insert milling of Aviation titanium alloy. For high-efficiency milling of complex surfaces, Zhao et al 30 used a fuzzy clustering algorithm to partition complex surfaces, used orthogonal test method to determine the minimum energy consumption and processing time, and comprehensively optimized cutting process parameters to achieve high-efficiency and energy-saving machining of complex surfaces.…”

Design and Research of Symmetrical Multi-Throttle Thrust Hydrostatic Bearing Based on Comparative Analysis of Various Meshes

“…The primary conditions for achieving ultraprecision processing are processing equipment represented by precision machine tools and inspection equipment represented by precision turntables. The precision spindle system, as the "heart" of such equipment, determines their processing and inspection accuracy [2,3]. In this precision rotating equipment, aerostatic bearings mainly provide a stable rotation reference for the spindle [4,5].…”