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Vol. 35 No. 4 (2025): JST: Engineering and Technology for Sustainable Development (10/2025)
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Research article
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Do, M. T., Bui, K. H., Hoang, N. D., Nguyen, K. H., Ngo, V. H., & Duong, X. B. Optimizing the Form Error of Al6061 Spherical Surfaces in Single-Point Diamond Turning Using Particle Swarm Optimization Algorithm. Engineering and Technology For Sustainable Development, 35(4), 043-051. Retrieved September 30, 2025, from https://jst.vn/index.php/etsd/article/view/1068

Optimizing the Form Error of Al6061 Spherical Surfaces in Single-Point Diamond Turning Using Particle Swarm Optimization Algorithm

Manh Tung Do1, Kim Hoa Bui2, Nghia Duc Hoang2, Kim Hung Nguyen2, Viet Hung Ngo2, Xuan Bien Duong2,
1 Faculty of Mechanical Engineering, Le Quy Don Technical University, Ha Noi, Vietnam
2 Technology Center, Le Quy Don Technical University, Ha Noi, Vietnam

Main Article Content

Abstract

The paper investigates optimizing form accuracy in Al6061 spherical surface (SS) machining through single-point diamond turning (SPDT) with the swarm optimization (PSO) algorithm. The optimization problem is implemented on the basis of building the relationship between profile accuracy or form error (FE) with cutting parameters including spindle speed (n-rev/min), feed rate (f-mm/min), and depth of cut (ap-μm). Based on the data collection from 15 experiments in the Box-Behnken (BB) model with the specialized software Design Expert support, the modeling results show a high agreement between the predicted data and the actual measured values with high reliability (R2 = 0.9428). By using the PSO algorithm, the optimal FE value of 0.95 μm was found, corresponding to the technological parameter set of n equal 1746 rev/min, f equal 5 mm/min, and ap equal 8 μm. This research significantly lays the foundation for controlling, predicting, and optimizing the FE factor of SS, particularly for Al6061 material and generally for other materials. Moreover, these results will further enhance the SPDT machining of more complex surfaces and reduce optical errors.

Keywords

SPDT, form error, PSO, Al6061

Article Details

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