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外文翻译--响应曲面法在最优化切削条件下获得最小表面粗糙度的应用 英文版.pdf

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外文翻译--响应曲面法在最优化切削条件下获得最小表面粗糙度的应用 英文版.pdf

JOURNALOFMATERIALSPROCESSINGTECHNOLOGY170200511–16APPLICATIONOFRESPONSESURFACEMETHODOLOGYINTHEOPTIMIZATIONOFCUTTINGCONDITIONSFORSURFACEROUGHNESSHOKTEMA,∗,TERZURUMLUB,HKURTARANBADEPARTMENTOFMECHANICALENGINEERING,UNIVERSITYOFKOCAELI,41420KOCAELI,TURKEYBDEPARTMENTOFDESIGNANDMANUFACTURINGENGINEERING,GIT,41400GEBZE,KOCAELI,TURKEYRECEIVED16JULY2004;RECEIVEDINREVISEDFORM12MARCH2005;ACCEPTED12APRIL2005ABSTRACTTHISPAPERFOCUSESONTHEDEVELOPMENTOFANEFFECTIVEMETHODOLOGYTODETERMINETHEOPTIMUMCUTTINGCONDITIONSLEADINGTOMINIMUMSURFACEROUGHNESSINMILLINGOFMOLDSURFACESBYCOUPLINGRESPONSESURFACEMETHODOLOGYRSMWITHADEVELOPEDGENETICALGORITHMGARSMISUTILIZEDTOCREATEANEFFICIENTANALYTICALMODELFORSURFACEROUGHNESSINTERMSOFCUTTINGPARAMETERSFEED,CUTTINGSPEED,AXIALDEPTHOFCUT,RADIALDEPTHOFCUTANDMACHININGTOLERANCEFORTHISPURPOSE,ANUMBEROFMACHININGEXPERIMENTSBASEDONSTATISTICALTHREELEVELFULLFACTORIALDESIGNOFEXPERIMENTSMETHODARECARRIEDOUTINORDERTOCOLLECTSURFACEROUGHNESSVALUESANEFFECTIVEFOURTHORDERRESPONSESURFACERSMODELISDEVELOPEDUTILIZINGEXPERIMENTALMEASUREMENTSINTHEMOLDCAVITYRSMODELISFURTHERINTERFACEDWITHTHEGATOOPTIMIZETHECUTTINGCONDITIONSFORDESIREDSURFACEROUGHNESSTHEGAREDUCESTHESURFACEROUGHNESSVALUEINTHEMOLDCAVITYFROM0412H9262MTO0375H9262MCORRESPONDINGTOABOUT10IMPROVEMENTOPTIMUMCUTTINGCONDITIONPRODUCEDFROMGAISVERIFIEDWITHTHEEXPERIMENTALMEASUREMENT2005ELSEVIERBVALLRIGHTSRESERVEDKEYWORDSMILLING;CUTTINGCONDITIONS;SURFACEROUGHNESS;INJECTIONMOLDING;RESPONSESURFACEMETHODOLOGY;GENETICALGORITHM1TRIBMILLINGDUCINGPARTST6AIRCRAFTASTENSILETICOFFSURFFIRRE09240136/DOI101016/JJMATPROTEC200504096INTRODUCTIONRECENTDEVELOPMENTSINMANUFACTURINGINDUSTRYHAVECONUTEDTOTHEIMPORTANCEOFCNCMILLINGOPERATIONS1,2PROCESSISREQUIREDTOMAKEMOLDPARTSUSEDFORPROPLASTICPRODUCTSITISALSOPREFERREDINMACHININGMOLDMADEOFALUMINUM7075T6MATERIALALUMINUM7075MATERIALASCHOSENINTHISSTUDYISCOMMONLYUTILIZEDINANDDIE/MOLDINDUSTRIESDUETOSOMEADVANTAGESSUCHHIGHRESISTANCE,GOODTRANSMISSION,HEATTREATABLEANDHIGHSTRENGTH3,4THEQUALITYOFPLASTICPRODUCTSMANUFACTUREDBYPLASINJECTIONMOLDINGPROCESSISHIGHLYINFLUENCEDBYTHATMOLDSURFACESOBTAINEDFROMTHEMILLINGPROCESSSURACEQUALITYOFTHESEPRODUCTSISGENERALLYASSOCIATEDWITHACEROUGHNESSANDCANBEDETERMINEDBYMEASURINGSURACEROUGHNESS5SURFACEROUGHNESSISEXPRESSEDASTHEGULARITIESOFMATERIALRESULTEDFROMVARIOUSMACHINING∗CORRESPONDINGAUTHORTEL902627423290;FAX902627424091EMAILADDRESSHOKTEMKOUEDUTRHOKTEMOPERATIONSFSYMBOL,METICMEANANSURFTINGSUCHWDITIONSMACHININGTHISDITIONSSUCHMODELSTOOLINBEEN718–SEEFRONTMATTER2005ELSEVIERBVALLRIGHTSRESERVEDINQUANTIFYINGSURFACEROUGHNESS,AVERAGESURACEROUGHNESSDEFINITION,WHICHISOFTENREPRESENTEDWITHRAISCOMMONLYUSEDTHEORETICALLY,RAISTHEARITHAVERAGEVALUEOFDEPARTUREOFTHEPROFILEFROMTHELINETHROUGHOUTTHESAMPLINGLENGTH6RAISALSOIMPORTANTFACTORINCONTROLLINGMACHININGPERFORMANCEACEROUGHNESSISINFLUENCEDBYTOOLGEOMETRY,FEED,CUTCONDITIONSANDTHEIRREGULARITIESOFMACHININGOPERATIONSASTOOLWEAR,CHATTER,TOOLDEFLECTIONS,CUTTINGFLUID,ANDORKPIECEPROPERTIES7,11,16THEEFFECTOFCUTTINGCONFEED,CUTTINGSPEED,AXIAL–RADIALDEPTHOFCUTANDTOLERANCEONSURFACEROUGHNESSISDISCUSSEDINSTUDYSEVERALRESEARCHERSHAVESTUDIEDTHEEFFECTOFCUTTINGCONINMILLINGANDPLASTICINJECTIONMOLDINGPROCESSESASINVACUUMSEALEDMOLDINGPROCESS5ANALYTICALHAVEBEENCREATEDTOPREDICTSURFACEROUGHNESSANDLIFEINTERMSOFCUTTINGSPEED,FEEDANDAXIALDEPTHOFCUTMILLINGSTEELMATERIAL8,9ANEFFECTIVEAPPROACHHASALSOPRESENTEDTOOPTIMIZESURFACEFINISHINMILLINGINCONEL1012PROCESSINGFORSURFOPEDMETHODOLOGYMODELDEGENETICLEADINGISAXIAL–RADIALDICTEDEPRESENTTUREPOLYNOMIALNATESGASOPTIMIZATIONTIONS221THEMENTSESIDERINGAXIALINGCARRIEDCUTTINGISBASEDMILLINGCONDITIONSMILLINGFROM2210TLODESIGNCUTTINGFEED,CUTTINGAXIALRADIALMACHININGFIG1MOLDPARTISPVDALTINCOATEDWITHSOLIDCARBIDEITHASTHEHELIXANGLEOF45◦ANDRAKEANGLEOF10◦MACHININGEXPERIMENTSAREPERFORMEDINTHEMOLDCAVITYONALUMINUM7075T6BLOCKWITHDIMENSIONSOF120MM120MM50MMTHECHEMICALCOMPOSITIONOFWORKPIECEMATERIALISGIVENINTHEFOLLOWINGSPECIFICATIONWT16CU,25MG,023CR,540ZNTHEHARDNESSOFWORKPIECEISMEASUREDAS150BHNTHEMECHANICALPROPERTIESOFALUMINUMMATERIALARETENSILESTRENGTHOF570MPA,YIELDSTRENGTHOF505MPA,SHEARSTRENGTHOF330MPAANDELONGATIONOF11SURFACEROUGHNESSISMEASUREDWITHSURFTEST301PROHOKTEMETAL/JOURNALOFMATERIALSINTHISSTUDY,AFOURTHORDERRESPONSESURFACERSMODELPREDICTINGSURFACEROUGHNESSVALUESINMILLINGTHEMOLDACESMADEOFALUMINUM7075T6MATERIALISDEVELINGENERATINGTHERSMODELSTATISTICALRESPONSESURFACERSMISUTILIZEDTHEACCURACYOFTHERSISVERIFIEDWITHTHEEXPERIMENTALMEASUREMENTTHEVELOPEDRSMODELISFURTHERCOUPLEDWITHADEVELOPEDALGORITHMGATOFINDTHEOPTIMUMCUTTINGCONDITIONTOTHELEASTSURFACEROUGHNESSVALUECUTTINGCONDITIONREPRESENTEDWITHCUTTINGPARAMETERSOFFEED,CUTTINGSPEED,DEPTHOFCUTANDMACHININGTOLERANCETHEPREOPTIMUMCUTTINGCONDITIONBYGAISVALIDATEDWITHANXPERIMENTALMEASUREMENTTHERSMODELANDGADEVELOPEDANDUTILIZEDINTHISSTUDYSEVERALADVANTAGESOVEROTHERMETHODSINTHELITERATHERSMODELISAHIGHERORDERANDMORESOPHISTICATEDMODELWITHSUFFICIENTACCURACYTHEGAELIMITHEDIFFICULTYOFUSERDEFINEDPARAMETERSOFTHEEXISTINGDETAILSOFTHERSMODELGENERATIONBYRSMANDTHEPROCESSBYGAAREGIVENINTHEFOLLOWINGSECEXPERIMENTALPROCEDURESPLANOFEXPERIMENTSANIMPORTANTSTAGEOFRSMODELGENERATIONBYRSMISPLANNINGOFEXPERIMENTSINTHISSTUDY,CUTTINGEXPERIAREPLANNEDUSINGSTATISTICALTHREELEVELFULLFACTORIALXPERIMENTALDESIGNCUTTINGEXPERIMENTSARECONDUCTEDCONFIVECUTTINGPARAMETERSFEEDFT,CUTTINGSPEEDVC,DEPTHOFCUTAA,RADIALDEPTHOFCUTARANDMACHINTOLERANCEMTOVERALL35243CUTTINGEXPERIMENTSAREOUTLOW–MIDDLE–HIGHLEVELOFCUTTINGPARAMETERSINSPACEFORTHREELEVELFULLFACTORIALEXPERIMENTALDESIGNSHOWNINTABLE1RANGESOFCUTTINGPARAMETERSARESELECTEDONRECOMMENDATIONOFSANDVIKTOOLCATALOGUE12OPERATIONSAREPERFORMEDATTHEDETERMINEDCUTTINGONADECKELMAHODMU60PFIVEAXISCNCMACHINESURFACEROUGHNESSRAVALUESAREMEASUREDTHEMOLDSURFACESTOOLANDMATERIALCUTTINGTOOLUSEDINEXPERIMENTSHASTHEDIAMETEROFMMFLATENDMILLWITHFOURTEETHTHEMATERIALOFTHETOOLABLE1W–MIDDLE–HIGHLEVELSOFCUTTINGPARAMETERSINTHREELEVELFULLFACTORIALOFEXPERIMENTPARAMETERSTHREELEVELVALUESFTMM/TOOTH008–0105–013SPEED,VCM/MIN100–200–300DEPTHOFCUT,ARMM03–05–07DEPTHOFCUT,ARMM1–15–2TOLERANCE,MTMM0001–00055–001FILOMETERPLINGMATHEMATICALVASTIMESMODEL23THECATIONSUTILIZEDPOSITIONANDMINUMORTHOSEIS24MANUFGRATEDCNCFTECHNOLOGY170200511–16ATTRAVERSELENGTHOF25MMALONGCENTERLINEOFSAMCONVERTINGTHEMEASUREMENTINTOANUMERICALVALUE,DEFINITIONOFRAISUSEDSINCETHISWAYOFCONERSIONISCOMMONINTHELITERATUREITISADOPTEDINTHISSTUDYWELL7–9EACHRAMEASUREMENTISREPEATEDATLEASTTHREEAVERAGEOFTHREERAVALUESISSAVEDTOESTABLISHRSMOLDPARTSTHEMOLDPARTUSEDINTHISSTUDYISUTILIZEDTOPRODUCECOMPONENTSOFANORTHOSEPARTINBIOMECHANICALAPPLIITISSHOWNINFIG1ORTHOSEPARTSAREGENERALLYINWALKINGAPPARATUSTHATHOLDSHUMANLEGSINSTABLEDURINGWALKINGITBINDSTHEKNEECAPREGIONOFLEGISEQUIPPEDWITHCYLINDRICALBARSTHATAREMADEOFALUMATERIALINDIAMETEROF12MMANDLENGTHOF300MMPARTCONSISTSOFTHREEMAINCOMPONENTS;ONEOFTHEMEMPLOYEDASTHEWORKINGMODELINTHISSTUDYMANUFACTURINGTHECOMPONENTSOFORTHOSEPARTTHREEMACHININGPROCESSESAREIMPLEMENTEDINORDERTOACTUREEACHCOMPONENTOFTHEORTHOSEPARTINANINTEMANNERFIRSTLY,THESELECTEDCOMPONENTISMACHINEDINMILLINGMACHINERAVALUESARETHENTAKENFROMTHESURACESINTHEMOLDCAVITYSECONDLY,PLASTICPRODUCTISINJECTEDPROCESSINGINACETALMATERIALSITYVISCOSITYFINALLYINGILLUSTRATED3SURFSTATISTICALNIQUEPHASEHOKTEMETAL/JOURNALOFMATERIALSFIG2THEPARTSOBTAINEDFROMTHREEFIG3THESTAGESTAKENINCREATINGARESPONSESURFACEMODELBYRSMPLASTICINJECTIONMACHINEPRODUCEDBYARBURGPOLYPOMC9021MATERIALISUSEDTOINJECTTHEPOLYMERTHEPROPERTIESOFPOLYMERMATERIALHASTHEDENOFSOLUTION12G/CM3,THEEJECTEDTEMPERATUREOF165◦C,OF50PASANDMELTFLOWFILLRATEOF08CM3/MIN,NETCASTINGPROCESSISAPPLIEDFORPRODUCINGDIECASTPARTMOLDPART,PLASTICPRODUCTANDDIECASTINGPARTAREINFIG2RESPONSESURFACEMODELFORSURFACEROUGHNESSRSMODEL,WHICHISANANALYTICALFUNCTION,INPREDICTINGACEROUGHNESSVALUESISDEVELOPEDUSINGRSMRSMUSESDESIGNOFEXPERIMENTEXPERIMENTALDESIGNTECHANDLEASTSQUAREFITTINGMETHODINMODELGENERATIONITISSUMMARIZEDINFIG3RSMWASORIGINALLYDEVELOPEDANDISFWHEREOFTOMAINGALLMODELSGENERATEDBECREATINGMINEDFORDATATRAININGDATALIZEDVRATHERSETFROUGHNESSTHEFIG4COMPARISONOFEXPERIMENTALMEASUREMENTSTECHNOLOGY170200511–1613MACHININGPROCESSFORTHEMODELFITTINGOFPHYSICALEXPERIMENTSBYBOXDRAPER13ANDLATERADOPTEDINOTHERFIELDSRSMODELFORMULATEDASFOLLOWINGPOLYNOMIALFUNCTIONNSUMMATIONDISPLAYNSUMMATIONDISPLAYNSUMMATIONDISPLAYA0I1AIXII1J1AIJXIXJ1A0,AIANDAIJARETUNINGPARAMETERSANDNISTHENUMBERMODELPARAMETERSIEPROCESSPARAMETERSINTHISSTUDY,CREATERSMODEL,ACOMPUTERPROGRAMHASBEENWRITTENINTLABPROGRAMMINGLANGUAGETHERSPROGRAMDEVELOPEDHASTHECAPABILITYOFCREATRSPOLYNOMIALSUPTO10THORDERIFSUFFICIENTDATAEXISTCROSSTERMSIEINTERACTIONSBETWEENPARAMETERSINTHECANBETAKENINTOACCOUNTRSMODELSCANALSOBEINTERMSOFINVERSEOFPARAMETERSTHATIS,XICANREPLACEDAS1XIIEINVERSELYINRSMODELIFDESIRED,INTHERSMODELS,243SURFACEROUGHNESSVALUESDETERBASEDONTHREELEVELFULLFACTORIALEXPERIMENTALDESIGNFIVEPARAMETERSFT,VC,AA,ARANDMTAREUSEDTHE243SETSFORSURFACEROUGHNESSAREDIVIDEDINTOTWOPARTS;DATASETANDTHECHECKIETESTDATASETTRAININGSETINCLUDES236SURFACEROUGHNESSVALUESANDISUTIINMODELFITTINGPROCEDUREBECAUSEOFLARGENUMBEROFALUESANDTOSAVESPACE,TRAININGDATAISSHOWNINFIG4,THANINATABLEINFIG4,ABSCISSAINDICATESTHEDATANUMBERANDTHEORDINATEINDICATESTHECORRESPONDINGSURACEROUGHNESSVALUECHECKDATASETSINCLUDESEVENSURFACEVALUESANDAREUSEDINCHECKINGTHEACCURACYOFRSMODELCHECKDATASETSARESHOWNINTABLE2THEYWITHRSPREDICTIONFORSURFACEROUGHNESS14PROCESSINGTTHESET1234567TTHERECIPROCALAREINCHECKTOPROGRAMWITHTAOFRFITSTHEDATA205ACCURACCUTTING4R41SURFPOSSIBLEHOKTEMETAL/JOURNALOFMATERIALSABLE2DATASETUSEDFORCHECKINGTHEACCURACYOFRSMODELNUMBERCUTTINGCONDITIONSFTVCAAARMT010520007100010105200071500010105200031000550082000715000550081000720005500820003150010105200052001ABLE3ACCURACYERROROFSEVERALRSMODELSFLAGFIRSTORDERSECONDORDERTHIRDORDERFOURTHORDER000002774827001002597285829500001524109402991100027266348205011002597055255000115491053727111002587035725011102757059281111153031054727SELECTEDFROM243DATASETSTOSHOWAGOODDISTRIBUTIONTHECUTTINGPARAMETERS’SPACEANDTHEREBYTOHAVEAGOODONTHEACCURACYOFTHERSMODELINTHISSTUDY,RSMODELSOFVARYINGORDERSFROMFIRSTORDERFOURTHORDERARECREATEDANDTESTEDWITHTHEDEVELOPEDSEVERALRSMODELCREATEDAREDEMONSTRATEDALONGTHEIRACCURACYERRORSINTABL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