Coaxiality error analysis and optimization of cylindrical parts of CNC turning process

Abstract High precision rotary shafts with precise geometrical tolerances are generally mounted a micron level clearance between the gears and casing during operation in industrial applications. Dynamics cyclic loads inevitable most of these applications which has an adverse effect on fatigue life critical parts. Ensuring close dimensional coaxiality machining is highly desirable, as it affects characteristics many Thus, control error plays vital role rotating high machine tools. However, use would drastically increase cost manufacturing. cost-effective process that could potentially reduce importance. The present research efforts made attempt to achieve minimum cylindrical machined parts by optimizing parameters (cutting speed, feed rate, depth cut cutting tool nose radius). Experiments planned, viz. central composite design matrix statistical analysis determine influence high-strength Al 7075 alloy applying response surface methodology. Feed rate factors showed significant error. All non-linear error, defines strong interaction factor effects. empirical equations derived were used minimize determining set parameters, Big-Bang Big Crunch Rao (Rao-1, Rao-2 Rao-3) algorithms. algorithms outperform algorithm both computation effort solution accuracy. results experimentally verified, resulted reduced equal 1.013 µm 72.6% improvement compared CCD experiments.