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Cutting parameters optimization for MRR under the constraints of surface roughness and cutter breakage in micro-milling process

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Abstract

Selection of cutting parameters in micro-milling operations is essential for improving machining efficiency and quality, and prolonging the micro-milling tool life. The increase of material removal rate (MRR) always means the increase of cutting parameters, which may lead to poor surface quality and micro-milling tool failure, even cutter breakage. An optimization approach based on genetic algorithm is used to achieve the maximum MRR under the constraints of surface roughness and cutter breakage. A theoretical model for predicting micro-milling cutter breakage is presented and micro-milling experiments were conducted to establish statistical models of cutter breakage and surface roughness. The optimized results were achieved under the constraints of the specified surface roughness and compared under the different surface roughness limitation. We find that the optimized results improve the machining efficiency and quality in micro- milling and is affected by constraint conditions complicatedly.

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Authors and Affiliations

  1. Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, No. 2 LingGong Road, DaLian, LiaoNing Province, 116026, China

    Xiaohong Lu, Haixing Zhang & Zhenyuan Jia

  2. The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA, 30332-0405, USA

    Yixuan Feng & Steven Y. Liang

Authors
  1. Xiaohong Lu
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  2. Haixing Zhang
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  3. Zhenyuan Jia
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  4. Yixuan Feng
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  5. Steven Y. Liang
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Correspondence to Xiaohong Lu.

Additional information

Recommended by Associate Editor Yongho Jeon

Xiaohong Lu is an Associate Professor with the School of Mechanical Engineering, Dalian University of Technology, Dalian, China. She received her Ph.D. in Mechanical Engineering from Dalian University in 2007. Her current research interests include precision machining and measuring techniques, computer- aided testing and control technologies.

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Lu, X., Zhang, H., Jia, Z. et al. Cutting parameters optimization for MRR under the constraints of surface roughness and cutter breakage in micro-milling process. J Mech Sci Technol 32, 3379–3388 (2018). https://doi.org/10.1007/s12206-018-0641-7

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  • DOI: https://doi.org/10.1007/s12206-018-0641-7

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