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<p>The geometric parameters of chip breaker grooves exhibit complex nonlinear coupling effects on both chip breaking performance and cutting force, rendering single-objective optimization inadequate for achieving an optimal engineering compromise. This paper proposes a multi-objective optimization methodology for the chip breaker groove geometry of turning inserts through the systematic integration of finite element simulation, response surface modeling, and a hybrid intelligent algorithm. Taking cemented carbide inserts for turning SUS304 stainless steel as the investigation object, a three-dimensional finite element model of the cutting process is first established. Based on the complementary sensitivities of chip breaking performance and cutting force, three representative groove parameters were selected. Their nonlinear and interaction effects were then quantified using central composite design and response surface methodology, yielding second-order regression models for <InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(\:Q\:\)</EquationSource> </InlineEquation>and <InlineEquation ID="IEq2"> <EquationSource Format="TEX">\(\:F\:\)</EquationSource> </InlineEquation>with <InlineEquation ID="IEq3"> <EquationSource Format="TEX">\(\:{R}^{2}\:\)</EquationSource> </InlineEquation>values of 0.9438 and 0.9459, respectively. On this basis, a combined subjective–objective weighting strategy is introduced, and a hybrid genetic algorithm–particle swarm optimization framework is adopted to simultaneously maximize chip breaking performance and minimize cutting force. The optimal groove parameters are determined as a rake angle of 15°, a cutting edge height of 0.13&#xa0;mm, and a backwall angle of 31.9°. Comparative experiments demonstrate that the optimized insert yields a 19.5%–70.0% improvement in chip breaking performance and a 5.1%–19.0% reduction in cutting force over a wide range of cutting parameters, while the chip morphology transforms from continuous long chips into desirable C-shaped chips. This study overcomes the single-objective limitation inherent in conventional chip breaker design, and the established FEM–RSM–HGA integrated framework provides a systematic theoretical foundation and a viable technical route for the digital design of high-performance cutting tools.</p>

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Multi-objective optimization of chip breaker groove geometry for turning inserts and investigation of cutting performance based on an integrated FEM–RSM–HGA framework

  • 期刊论文

  • 发表日期：

    2026年8月5日

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  • Ruitao Peng,
  • Jinchi Yao,
  • Jiangxiong Gao,
  • Gaoli Kuang,
  • Linfeng Zhao

摘要

The geometric parameters of chip breaker grooves exhibit complex nonlinear coupling effects on both chip breaking performance and cutting force, rendering single-objective optimization inadequate for achieving an optimal engineering compromise. This paper proposes a multi-objective optimization methodology for the chip breaker groove geometry of turning inserts through the systematic integration of finite element simulation, response surface modeling, and a hybrid intelligent algorithm. Taking cemented carbide inserts for turning SUS304 stainless steel as the investigation object, a three-dimensional finite element model of the cutting process is first established. Based on the complementary sensitivities of chip breaking performance and cutting force, three representative groove parameters were selected. Their nonlinear and interaction effects were then quantified using central composite design and response surface methodology, yielding second-order regression models for \(\:Q\:\) and \(\:F\:\) with \(\:{R}^{2}\:\) values of 0.9438 and 0.9459, respectively. On this basis, a combined subjective–objective weighting strategy is introduced, and a hybrid genetic algorithm–particle swarm optimization framework is adopted to simultaneously maximize chip breaking performance and minimize cutting force. The optimal groove parameters are determined as a rake angle of 15°, a cutting edge height of 0.13 mm, and a backwall angle of 31.9°. Comparative experiments demonstrate that the optimized insert yields a 19.5%–70.0% improvement in chip breaking performance and a 5.1%–19.0% reduction in cutting force over a wide range of cutting parameters, while the chip morphology transforms from continuous long chips into desirable C-shaped chips. This study overcomes the single-objective limitation inherent in conventional chip breaker design, and the established FEM–RSM–HGA integrated framework provides a systematic theoretical foundation and a viable technical route for the digital design of high-performance cutting tools.