Abstract
<jats:p>Introduction. Machining of thin-walled parts represents one of the most challenging problems in modern mechanical engineering, particularly in the aerospace industry, precision instrumentation, and other high-technology sectors where requirements for geometric accuracy are critical. The low bending stiffness of such structures causes extreme sensitivity to the forces arising during machining: elastic deformations induced by the combined action of cutting forces and clamping forces lead to significant deviations from specified dimensions and shape, constituting one of the primary causes of manufacturing defects. Conventional methods of cutting parameter selection, based on reference data and operator experience, do not provide the capabilities for quantitative prediction of thin-walled workpiece deformation behavior and fail to account for the specifics of their deformation behavior. This problem is particularly relevant in the context of developing next-generation hybrid machine tools integrating mechanical and surface-thermal technological operations, where scientifically based selection of machining parameters is an essential condition for ensuring the required product quality. The purpose of the present work is to develop, implement in software, and comprehensively verify an intelligent decision support system (DSS) prototype designed for the scientifically based selection of optimal turning parameters to minimize elastic deformation of thin-walled parts as an integral component of a design methodology for hybrid metal-cutting systems. Research methods. The system is based on an analytical mathematical model establishing the functional relationship between cutting parameters, the resultant cutting force, and the elastic deflection of the workpiece, calculated using the cantilever beam model. An iterative multi-parameter optimization algorithm with the objective function of minimizing maximum deflection was implemented. Verification of system effectiveness was conducted on two representative thin-walled parts – a bushing made of steel 45 and a ring made of AK9ch aluminum alloy – through comprehensive simulation that included: verification of process technological feasibility in the SprutCAM CAM system and evaluation of deformation fields via static finite element analysis in the ANSYS Mechanical CAE system. Results and discussion. Application of the developed DSS provided a significant reduction in force exerted on the workpiece: the tangential cutting force component decreased by a factor of 2.1 for the steel bushing and by a factor of 10.8 for the aluminum ring. Finite element analysis confirmed a reduction in maximum elastic deformation of 72.3% (from 0.0602 to 0.0167 mm) for the steel bushing and of 87.9% (from 0.0422 to 0.0051 mm) for the aluminum ring. A key technological result is that deformation values after optimization do not exceed the design tolerances for cylindricity. SprutCAM simulation confirmed the complete technological feasibility of the machining processes. The obtained results demonstrate the prospects of integrating intelligent decision-making systems into the design methodology of hybrid machine tools to enhance the competitiveness of the domestic machine tool industry.</jats:p>