Optimization of 3D surface roughness induced by milling operation for adhesive-sealing

Abstract In automotive engine manufacturing, the adhesive-sealing performance between two machined surfaces is closely related with machined surface topography induced by face milling. Joint researches in machining and adhesive are needed to enhance the sealing performance. This paper aims to enhance a comprehensive understanding of the impact of milling parameters and machined surface 3D roughness on adhesive-sealing performance. Three experiments were conducted in this research: a set of milling tests through design of experiment (DoE) to obtain surfaces with different surface qualities, 3D measurement of machined surface topographies to identify the surface roughness parameters, and tensile tests to characterize the adhesive-sealing performance of machined surfaces. Then the relationships of surface roughness parameters, milling parameters and functional sealing performance were modeled and optimized by means of response surface methodology (RSM) and genetic algorithm (GA). This research provides manufactures a reliable approach on selecting milling parameters and monitoring surface roughness.