Optimisation of tungsten alloy cutting process parameters considering the effect of electric pulse parameters based on the Isight platform

Abstract To address the inefficiency associated with experimental iterations in traditional multi-objective parameter optimisation, this study develops an integrated framework for rapid and simultaneous optimisation of multiple parameters. Focusing on determining the optimal process parameters for electroplasticity-assisted turning of 93WNiFe alloy, a multi-objective collaborative optimisation framework was developed by integrating Abaqus simulation software into the Isight multi-objective optimisation platform, combined with Response Surface Methodology (RSM). Firstly, an orthogonal experimental design was employed to evaluate the effects of cutting parameter variations on key machining responses. Following this, response surface models were constructed to mathematically characterise the relationships between optimisation variables and performance objectives. Finally, a multi-objective optimisation procedure was executed to simultaneously minimise cutting force and temperature while maximising tool life. Experimental results demonstrated that optimal cutting quality was achieved under the following combination of parameters: a tool rake angle ( γ 0 ) of 11°, a pulse frequency ( f ) of 344.18 Hz, a feed rate ( f v ) of 0.3 mm rev −1 , a voltage ( U ) of 85 V, and a tool clearance angle ( α 0 ) of 8°. Under these optimised conditions, cutting resultant forces ( F r ) decreased from 211.24 N and 300.58 N to 123.31 N, achieving reductions of 41.6% and 59%, respectively. Similarly, cutting temperatures ( T ) declined from 289 °C and 269 °C to 133.39 °C, corresponding to reductions of 53.8% and 50.4%. Tool wear ( V tip ) performance also exhibited marked enhancement, with wear values dropping from 0.00932 mm and 0.03685 mm to 0.00423 mm. Validation experiments confirmed strong agreement between predicted and observed results, underscoring the robustness of the proposed methodology.