Milling optimisation of removal rate and accuracy with uncertainty: Part 1: parameter selection

Successful implementation of milling requires the selection of appropriate operating parameters. In this paper a semi-analytical modelling approach and multi-objective optimisation are used to select optimum spindle speed and axial depth. The trade-off curve of removal rate and surface location error is calculated. Some degree of robustness is achieved by calculating the surface location error as a moving average over an interval of spindle speeds. The stability boundary and a selected design are compared to experimental results. The results illustrate the need to be concerned with the robustness of the optimal designs. This is addressed in Part 2 of the paper.