Research on stability range of milling process parameters based on sensitivity analysis

Milling is extensively used in manufacturing various products and parts, making it a vital processing method in the industry. The rational choice of milling process parameters is crucial for controlling the roughness of the machined workpiece. The focus of this study is to analyze the stability range of milling process parameters for 2024 aluminum alloy and examine their influence on surface roughness. Through sensitivity analysis integrated with Box-Behnken experimental design and response surface modeling, the impact of these parameters on surface roughness is explored. The response surface method is utilized to develop a second-order regression model that establishes the quantitative relationship between surface roughness and the milling process parameters. Comprehensive relative sensitivity analysis (CRSA, which evaluates the combined effects of global parameter interactions via Monte Carlo simulations) and localized single-parameter sensitivity analysis (LSPSA, quantifying individual parameter sensitivity via derivative-based methods) are integrated to assess parameter sensitivity characteristics and establish stability ranges. The research findings demonstrate that within the experimentally investigated parameter space (n = 6000~9000 r/min, ae = 0.1~0.3 mm, ap = 0.03~0.05 mm, vf = 100~300 mm/min), the identified stability ranges are: spindle speed [7500 r/min~000 r/min], radial depth of cut [0.275 mm~0.300 mm], axial depth of cut [0.03 mm~0.05 mm], and feed rate [200 mm/min~250 mm/min]. This study provides a theoretical foundation for optimizing milling process parameters, while also offering guidance on controlling surface roughness and enhancing part performance.