Optimization of CNC Milling Parameters for Complex 3D Surfaces of SIMOLD 2083 Alloy Mold Core Utilizing Multiobjective Water Cycle Algorithm

Abstract

In this article, an effective multiobjective optimization approach is exploited to search for the best milling parameters for CNC for complex 3d surfaces of SIMOLD 2083 alloy mold core. To improve the quality responses, the cutting factors are optimized by a combination of Taguchi method (TM), response surface method (RSM), and multiobjective water cycle algorithm (MWCA). Firstly, the design for initial series experiments of the cutting factors was generated via the TM. Thereafter, the regression models between the cutting factors and the surface roughness of the machined workpiece surface as well as milling time are formed via applying the RSM. Moreover, analysis of variance and sensitivity analysis are also executed to define the influences and crucial contributions of cutting parameters on the surface roughness and milling time. The results of analysis of variance showed that the factors which have main effects on surface roughness were spindle speed (42.42%), feed rate (29.40%), and cutting depth (6.59%), respectively. Meanwhile, the feed rate with the influence of 92.6% was the most significant factor in controlling the milling time. Ultimately, based on mathematical models, the MWCA is performed to define the optimal factors. The optimal results indicated that the optimized surface roughness was about 0.260 μm and the milling time was roughly 1012.767 (s). In addition, the errors between forecasted results and experimental verifications for the surface roughness and milling time are 2.04% and 5.39%, respectively. Therefore, the results of experimental verifications are suitable with the forecasted results from the proposed optimization method. These results depicted that the proposed integration approach can define effectively the optimal cutting factors for CNC milling and expand to apply for complex multiobjective optimization problems.