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Efficient optimisation of machining processes based on technical specifications for surface roughness: application to magnesium pieces in the aerospace industry

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Abstract

Magnesium is one of the lightest metallic materials and is well known and widely used in the aeronautic and aerospace industries. The pieces machined in these industrial fields must satisfy stringent surface roughness requirements to achieve a product quality that conforms to the design specifications. The aim of this investigation is to optimise efficiently the dry turning of magnesium pieces to achieve a surface roughness within technical requirements. A cost-effective and flexible statistical optimisation procedure, which is based on the technical specifications of surface roughness as well as on a robust experimental design, identified different optimal cutting conditions that provide a surface finish which meets the roughness specifications in magnesium parts. Furthermore, as a consequence of such optimisation procedure, the machining time was reduced, and the aerospace companies could select among the optimal operating conditions by also considering productivity, safety and environment criteria to control production of the surfaces finish.

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Acknowledgments

The authors would like to thank Professor Miguel A. Sebastián (UNED) for some helpful suggestions during this research. Funding for this work was provided in part by the Spanish Ministry of Science and Innovation (Projects MTM2009-07800 and DPI2008-06771-C04-02) and by the Industrial Engineering School—UNED (Project REF2011-ICF03). The material used in the machining tests was obtained from the Engine Overhaul Shop of IBERIA L.A.E.S.A. OPERADORA, S.U.

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Authors and Affiliations

  1. Department of Statistics and Operation Research III, School of Statistics, Complutense University of Madrid (UCM), Av. Puerta de Hierro s/n, E28040, Madrid, Spain

    María Villeta

  2. Department of Manufacturing Engineering, Industrial Engineering School, National University of Distance Education (UNED), C/Juan del Rosal, 12, E28040, Madrid, Spain

    Beatriz de Agustina, José Manuel Sáenz de Pipaón & Eva María Rubio

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  1. María Villeta
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  2. Beatriz de Agustina
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  3. José Manuel Sáenz de Pipaón
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  4. Eva María Rubio
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Correspondence to María Villeta.

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Villeta, M., de Agustina, B., Sáenz de Pipaón, J.M. et al. Efficient optimisation of machining processes based on technical specifications for surface roughness: application to magnesium pieces in the aerospace industry. Int J Adv Manuf Technol 60, 1237–1246 (2012). https://doi.org/10.1007/s00170-011-3685-8

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  • DOI: https://doi.org/10.1007/s00170-011-3685-8

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