Enhancing face-milling efficiency of wood–plastic composites through the application of genetic algorithm–back propagation neural network

Abstract

ABSTRACT Wood–plastic composites (WPCs) have advanced physicochemical properties and are widely applied in various fields. How to achieve high-efficiency, high-quality machining of WPC is a pressing issue that WPC manufacturing enterprises need to address. To this end, this research focused primarily on improving the machinability of WPC with end milling experiments. In this work, a single-factor method was used to analyse the impact of axial milling depth, spindle speed, and tool rake angle on resultant forces and surface roughness. Main effects analysis was applied to explore the degree of influence of axial milling depth, spindle speed, and tool rake angle on cutting forces and surface roughness. Furthermore, three-dimensional characterisation techniques were utilised to analyse the surface morphology characteristics of WPC during end milling. Finally, a genetic algorithm–back propagation neural network was applied to develop prediction models for resultant force and surface roughness, and optimal milling conditions were identified as axial milling depth of 0.50 mm, spindle speed of 7841 r/min, and rake angle of 15°; these produced the lowest resultant force and surface roughness. The findings of this work are proposed as a guide for better cutting performance in the industrial production of WPC.