Single and Multi-response Optimization of Scroll Machining Parameters by the Taguchi Method

Abstract

The precision of scroll machining plays a crucial role in scroll compressor efficiency. However, the improvement in scroll surface quality usually comes at the cost of an increase in energy consumption, so a trade-off between surface quality and energy consumption is required. Here in, we concentrate on optimizing several scroll end milling parameters including depth of cut, feed rate, cutting speed, and radial depth of cut to enhance the efficiency of scroll compressors, which greatly influence manufacturing responses like cutting force, surface roughness, and machining time. First, a set of scroll milling experiments are conducted and analyzed by the Taguchi L25 orthogonal array. Then, a single response optimization is done by the Taguchi method to show the impact of the milling parameters on each single response. Furthermore, the Taguchi method associated with the desirability function is applied to optimize the multi-response outputs. According to the analysis of variance (ANOVA) for the single-response, feed rate is found the most significant factor, while the results of the multi-response analysis prove that depth of cut with 37.53% is the most significant factor for the entire system. Finally, a quadratic regression analysis is performed to verify the validation of optimized results. The results revealed a 44.04% improvement in machining time, accompanied by a 2.46% enhancement in composite desirability. This demonstrated a perfect fit between the measured and expected values, achieving a balance between surface quality and energy consumption. The optimization results provide a guidance for the high-surface quality machining of scrolls and could be directly applied in the manufacturing processes of scroll compressors.