Process Parameters Optimization for Desired Surface Roughness and Identification of Radial Cutter Runout Parametersin Micro-end-milling

• Main Authors: Hsiu-Shan Tsai, 蔡修善
• Other Authors: Yaw-Hong Kang
• Format: Others
• Language: zh-TW
• Published: 2014
• Online Access: http://ndltd.ncl.edu.tw/handle/ucnp27

碩士 === 國立高雄應用科技大學 === 機械與精密工程研究所 === 102 === The primarily process parameters in micro-end-milling are spindle speed, feed rate and axial depth of cut,etc. The decision of process parameters affectdirectly the surface quality of workpiece, manufacturing time and cost. This research aims to the SKD11 mold steel in micro-end-milling, applies experimental design and response surface methodology (RMS) to establish the relation of surface roughness to processing parameters, then takes it as the objective function of process parameters optimization for desired surface roughness of a biochip micro-channel when using four evolutionary algorithm methods, which are differential evolution (DE), hybrid particle swarm optimization (HPSO), particle swarm optimization (PSO) and genetic algorithm (GA), etc. In addition, the surface roughness can be predicted by a proposed theoretical analytical model. Finally, the micro-end-milling experiments are conducted with the optimal parameters obtained using those methods, compared with the desired, measured and predicted value of the surface roughness, it reveals that the result of HPSO method is the best. In addition, we derive the surface morphology parameters prediction model implicitly expressed in parametersof cutterrunoutbased on the measured topography surface height of the micro-milled workpiece, and Newton-Raphson methodis applied to solve the proposed model for the radial cutter runout and phase angle. According to the predictive surface topography height, the surface roughness values can then be calculated and comparedwith measured values, the error between both results only 3.01%. The results of this study showed that for SKD11 mold steel in micro-end-milling, the response surface methodology can be usedfor determining the objective function of the surface roughness optimization, and the HPSO method can obtain the best results for desired surface roughness of workpiece in micro-end-milling of SKD11. In addition, based on the proposed surface topography model and the measured values of experiment, the Newton-Raphson method canbe used successfully for solving the radial cutter runout and phase angle in micro-end-mill.