Milling Parameters Optimization of Al-Li Alloy Thin-Wall Workpieces Using Response Surface Methodology and Particle Swarm Optimization

To improve the milling surface quality of the Al-Li alloy thin-wall workpieces and reduce the cutting energy consumption.Experimental research on the milling processing of AA2195 Al-Li alloy thin-wall workpieces based on Response Surface Methodology was carried out.The single factor and interaction of milling parameters on surface roughness and specific cutting energy were analyzed,and the multi-objective optimization model was constructed.The Multiobjective Particle Swarm Optimization algorithm introducing the Chaos Local Search algorithm and the adaptive inertial weight was applied to determine the optimal combination of milling parameters.It was observed that surface roughness was mainly influenced by feed per tooth,and specific cutting energy was negatively correlated with feed per tooth,radial cutting depth and axial cutting depth,while cutting speed has a non-significant influence on specific cutting energy.The optimal combination of milling parameters with different priorities was obtained.The experimental results showed that the maximum relative error of measured and predicted values was 8.05%,and the model had high reliability,which ensured the low surface roughness and cutting energy consumption.It was of great guiding significance for the success of Al-Li alloy thin-wall milling with a high precision and energy efficiency.

Experimental technique to analyze the influence of cutting conditions on specific energy consumption during abrasive metal cutting with thin discs

Specific energy consumption is an important indicatorfora better understanding of the machinability of materials.The present study aims to estimate the specific energy consumption for abrasive metal cutting with ultrathin discs at comparatively low and medium feed rates.Using an experimental technique,the cutting power was measured at four predefined feed rates for S235JR,intermetallic Fe-Al(40%),and C45K with different thermal treatments.The variation in the specific energy consumption with the material removal rate was analyzed through an empirical model,which enabled us to distinguish three phenomena of energy dissipation during material removal.The thermal treatment and mechanical properties of materials have a significant impact on the energy consumption pattern,its corresponding components,and cutting power.Ductile materials consume more specific cutting energy than brttle materials.The specific cutting energy is the minimum energy required to remove the material,and plowing energy is found to be the most significant phenomenon of energy dissipation.