The comprehensive improvement of surface integrity in whirlwind milling a large screw

The surface integrity of a large screw in whirlwind milling was vital for the fatigue life. Firstly, the comprehensive evaluation of surface integrity (CESI) was modeled by the Analytic Hierarchy Process (AHP). The weights of selected important factors, such as surface roughness (Ra), surface residue stress (SRS), and full width at half maximum (FWHM), were calculated. Then aimed at minimizing Ra, SRS -200 MPa and maximizing FWHM, the single-factor improvements were achieved under different parameter combination, respectively. Lastly based on single-factor improvements, the CESI was markedly improved by 64% compared to factory processing. Thus, the proposed approach and methodology can be notably adequate for evaluating and improving the surface integrity comprehensively.