Reliability optimization of cutting parameters considering the diameter error of slender shaft

In slender shaft turning, any diameter error in the workpieces can cause cutting tool wear and poor machining accuracy. Published research ignores the integrated analysis of diameter error, the randomness of parameters, and optimization models. This paper sets material removal rate (MRR) as the optimization objective function and considers the randomness of cutting parameters in a reliability parameter optimization model design, under the constraint of diameter error. The cutting force is calculated based on the unequal shear zone model and is used in finite element analysis of the slender shaft, deriving the diameter error model. The derived complex error model is replaced by the Kriging fitting method, reducing the calculation time to less than 1 %. Single loop sequence optimization and reliability assessment (SORA) is used to optimize reliability. The results show significant improvement of the MRR, while the reliability of each constraint condition is close to 1.