Abstract
<jats:p>Introduction. The study addresses the challenge of selecting finishing turning parameters for a metal-composite system comprising a thin metal external layer (2 mm thick) produced by selective laser melting and containing an internal metal-polymer filler. The relevance of the work is driven by the need to ensure the machining quality of the outer surface while adhering to strict temperature constraints at the metal-polymer interface, imposed by the low thermal resistance of the filler material. Purpose of the work is to develop and implement a multi-criteria optimization approach for the finishing turning parameters of the metal-composite system. This approach is based on previously developed regression models for the interface temperature and cutting tool wear, and aims to minimize tool wear while satisfying temperature constraints and surface quality requirements. Methodology. The methodology is based on a previously developed 2T3-type regression model for predicting temperature at the metal-metal-polymer interface and a cutting tool wear model formulated as a generalized Fick-Taylor equation for a cemented carbide insert (grade AH6225). Using these models, a mathematical programming problem with a nonlinear temperature constraint is formulated and solved via the sequential quadratic programming (SQP) method within specified ranges of cutting speed, feed rate, and depth of cut. Results and discussion. The numerical implementation of the proposed approach yielded the domains of admissible and optimal finishing turning parameters for the metal-composite system, based on criteria of thermal load and tool wear. The depth of cut was identified as the dominant factor influencing the temperature at the metal-metal-polymer interface. It was shown that the temperature constraint defines the boundaries of the admissible parameter domain. Specific combinations of cutting speed, feed rate, and depth of cut were determined that simultaneously satisfy the polymer's temperature limit and ensure an acceptable wear level for the AH6225 carbide inserts.</jats:p>