Reliability Optimization of Process Parameters Considering Milling Surface Morphology

doi:10.12068/j.issn.1005-3026.2025.20230275

Abstract

Abstract:

Research is conducted on the ball end milling process with the aim of achieving reliable optimization of milling process parameters. Firstly， according to the motion trajectory of the ball end mill cutting edge， the surface morphology formed during machining is simulated using the Z-mapping （Z-MAP） algorithm， and the surface roughness （R_a） is introduced to measure the surface quality after machining. The accuracy of the surface morphology simulation model is validated through surface morphology analysis experiments. Then， considering the actual constraint conditions of the machining surface quality， the tool service life， and the uncertainty of process parameters during the machining process， a reliability optimization model for process parameters is established with spindle rotation speed， tool feed rate， axial cutting depth and radial cutting depth as the optimization variables， and maximizing the material removal rate （Q） as the optimization objective. Finally， the optimization model is solved using the grey wolf optimization algorithm to obtain the optimal process parameters， and the feasibility of the optimized results is verified through milling experiments.

Key words: ball end mill, Z-MAP algorithm, surface morphology, surface roughness, grey wolf optimization algorithm, reliability optimization

CLC Number:

TG 547

Xian-zhen HUANG, Xu WANG, Peng-fei DING, Zhi-yuan JIANG. Reliability Optimization of Process Parameters Considering Milling Surface Morphology[J]. Journal of Northeastern University(Natural Science), 2025, 46(3): 80-87.

Figures/Tables 10

References 23

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组别	n /(r·min^-1)	v /(mm·min^-1)	a_p/mm	f_p /mm
1	500	100	0.5	0.5
2	500	200	0.3	0.7
3	500	200	0.5	0.7
4	500	250	0.5	0.5
5	1 000	100	0.5	0.7
6	1 000	200	0.3	0.5
7	1 000	200	0.5	0.5
8	1 000	200	0.5	0.7

组别	n /(r·min^-1)	v /(mm·min^-1)	a_p/mm	f_p /mm
1	500	100	0.5	0.5
2	500	200	0.3	0.7
3	500	200	0.5	0.7
4	500	250	0.5	0.5
5	1 000	100	0.5	0.7
6	1 000	200	0.3	0.5
7	1 000	200	0.5	0.5
8	1 000	200	0.5	0.7

组别	表面粗糙度/μm		相对误差/%
组别	仿真值	实验值	相对误差/%
1	1.581	1.764	10.37
2	3.062	3.252	5.84
5	2.912	2.723	6.94
8	2.954	2.844	3.87

组别	表面粗糙度/μm		相对误差/%
组别	仿真值	实验值	相对误差/%
1	1.581	1.764	10.37
2	3.062	3.252	5.84
5	2.912	2.723	6.94
8	2.954	2.844	3.87

参数类型	n/(r·min^-1)	v /(mm·min^-1)	a_p/mm	f_p/mm	r₁	r₂	Q/(mm³·min^-1)
初始参数	500.0	100.0	0.3	0.3	—	—	9.0
确定性优化参数	1 389.142 4	247.817 9	0.695 0	0.495 5	0.401 2	0.985 7	85.341 7
可靠性优化参数	1 309.957 5	187.109 4	0.639 9	0.443 4	0.996 3	1.000 0	53.088 9