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Structural optimization design and application of variable helix angle end mill based on improved genetic algorithm

Tao Chen

Tao Chen

Automotive College, Sanmenxia PolytechnicSanmenxia, China
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Chen, Tao
  
19 mars 2025
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Publié en ligne: 19 mars 2025
Reçu: 08 oct. 2024
Accepté: 02 févr. 2025
DOI: https://doi.org/10.2478/amns-2025-0490
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© 2025 Tao Chen, published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Figure 1.

Structure optimization flowchart
Structure optimization flowchart

Figure 2.

Variation curve of flank wear of four milling tools with cutting length
Variation curve of flank wear of four milling tools with cutting length

Figure 3.

Variation curve of cutting force of four milling tools with cutting length
Variation curve of cutting force of four milling tools with cutting length

Figure 4.

Variation curve of workpiece finished surface roughness
Variation curve of workpiece finished surface roughness

Comparison results of the best scheme and control scheme

Milling structure Al7075-T6 TC4
This article Control This article Control
Spindle speed (r/min) 4600 4500 3300 3300
Axial depth (mm) 7.41 7.35 6.05 5.82
Radial depth (mm) 0.58 0.52 0.35 0.31
Average amount per tooth (mm) 0.04 0.07 0.06 0.07
Intertooth Angle (φp1) 97.5° 95° 97.5° 95°
Spiral Angle (β1) 45° 45° 36.5° 35°
Spiral Angle (β2) 46.5° 45° 35° 35°
SD 12.94 15.63 26.02 32.16
Material removal rate -69.72 -64.52 -20.94 -18.52

Side milling top 5 solutions in A17075-T6

Number 1 2 3 4 5
Spindle speed (r/min) 4600 4600 4600 4600 4600
Axial depth (mm) 7.41 7.41 7.1 6.57 6.82
Radial depth (mm) 0.58 0.58 0.58 0.58 0.58
Average amount per tooth (mm) 0.04 0.04 0.04 0.06 0.06
Intertooth Angle (φp1) 97.5° 97.5° 97.5° 97.5° 97.5°
Spiral Angle (β1) 45° 45° 45° 45° 45°
Spiral Angle (β2) 46.5° 46.5° 46.5° 46.5° 46.5°
SD 12.94 13.01 13.31 13.56 13.91
Material removal rate -69.72 -67.2 -66.83 -66.53 -66.48

Side milling top 5 solutions in TC4

Number 1 2 3 4 5
Spindle speed (r/min) 3300 3300 3300 3300 3300
Axial depth (mm) 5.9 5.95 6.05 6.88 5.95
Radial depth (mm) 0.35 0.35 0.35 0.35 0.35
Average amount per tooth (mm) 0.03 0.03 0.06 0.03 0.06
Intertooth Angle (φp1) 97.5° 97.5° 97.5° 97.5° 97.5°
Spiral Angle (β1) 36.5° 36.5° 36.5° 36.5° 36.5°
Spiral Angle (β2) 35° 35° 35° 35° 35°
SD 26.55 26.08 26.02 27.07 27.8
Material removal rate -19.56 -19.99 -20.94 -19.69 -20.28

Simulation and experimental results of Al7075-T6

Program number 1 2 3 4 5
Fx¯ experimental (N) 43.99 62.15 85.01 86.59 107.6
Fx¯ simulation (N) 50.14 68.73 95.84 98.30 119.89
Error value (%) 13.97% 10.59% 12.74% 13.52% 11.42%
Fy¯ experimental (N) 140.29 159.3 219.99 221.34 274.1
Fy¯ simulation (N) 152.33 165.08 238.43 242.41 295.95
Error value (%) 8.58% 3.63% 8.38% 9.52% 7.97%
Fz¯ experimental (N) 28.92 41.97 68.64 80.83 81.85
Fz¯ simulation (N) 32.68 42.75 75.86 84.75 93.78
Error value (%) 13.01% 1.87% 10.52% 4.85% 14.57%

Simulation and experimental results of TC4

Program number 1 2 3 4 5
Fx¯ experimental (N) 145.72 222.33 247.37 273.62 277.67
Fx¯ simulation (N) 153.53 228.18 259.94 285.71 284.36
Error value (%) 5.36% 2.63% 5.08% 4.42% 2.41%
Fy¯ experimental (N) 295.26 336.6 348.53 356.75 387.65
Fy¯ simulation (N) 313.03 362.92 357.91 367.49 397.38
Error value (%) 6.02% 7.82% 2.69% 3.01% 2.51%
Fz¯ experimental (N) 75.13 117.36 130.47 150.76 172.02
Fz¯ simulation (N) 85.82 134.30 142.41 169.03 196.57
Error value (%) 14.23% 14.43% 9.15% 12.12% 14.27%
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