Multidisciplinary Multi-objective Optimization Design of Hollow End Mill Based on Response Surface Method

In order to deal with the difficulty of removing sand chips in digitally machining sand molds without pattern with dry cutting, a hollow end mill was designed that can remove sand chips by pneumatic conveying. First, combined with simulation analysis and response surface method, a multidisciplinary multi-objective optimal model of hollow end mill was established to achieve good static and dynamic performance and good removing chips performance. Then, the Pareto optimal solutions were obtained using non-dominated Sorting Genetic Algorithm II (NSGA-II). Finally, the reliability of optimization results was verified by the simulation and experiments. The Pareto optimal results, compared with the initial design, show that the total deformation of tool nose relative to work piece reduces 0.1% on average, the first-order natural frequency increases averagely 0.8%, and the average wind velocity at the outlet of sand mold cavity increases averagely 10.2%, improving the overall performance of hollow end mill.