Fada Cai, Rongfei Xia
To achieve the multi-objective collaborative optimization of milling processes, orthogonal experiments are conducted to develop prediction models for vibration acceleration and milling force, and range analysis together with variance analysis are adopted to reveal the sensitivity of each milling parameter to machining performance. Taking low vibration, small milling force and high material removal rate (MRR) as optimization objectives, the Multi-Objective Whale Optimization Algorithm (MOWOA) is employed to tackle this multi-criteria optimization problem, and a set of Pareto non-dominated solutions with balanced trade-offs are acquired. By integrating the weight assignment of the Analytic Hierarchy Process (AHP) with the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS), comprehensive decision-making for all candidate schemes is implemented in accordance with practical machining requirements of users, and the optimal milling process parameters are determined. The results indicate an inherent trade-off among machining efficiency, milling load and machine tool vibration. An increase in the material removal rate will inevitably lead to simultaneous rises in milling force and machine tool vibration magnitude. The optimal combination of process parameters screened to meet comprehensive multi-objective requirements is spindle speed n = 12,000.00 r/min, feed rate vf = 1048.26 mm/min, and axial milling depth ap = 3.00 mm.