Delamination Prediction and Multi‐Objective Optimization in Ultrasonic Vibration‐Assisted Helical Milling (
UVHM
) of
UHMWPE
Composites
Yaoting Wang, Lei Zheng, Zhiming Jiang, Jinqi Zai, Haoxiang Wang, Shuying Yang, Yong Feng ABSTRACT
Ultrasonic vibration‐assisted helical milling (UVHM) of ultra‐high molecular weight polyethylene (UHMWPE) fiber composites was experimentally investigated. Single‐factor experiments showed that UVHM reduced the delamination ratio by 2.6%–7.3% compared with conventional helical milling, and an energy accumulation framework based on intermittent cutting was proposed to elucidate the suppression mechanism. A Box–Behnken design ( n = 5000–7000 r/min, ng = 50–70 r/min, ap = 0.10–0.20 mm/r) was then employed to establish a second‐order RSM delamination model (R2 = 0.9888), with pitch identified as the dominant factor (F = 329.39). An RSM‐GRA nested strategy was developed, incorporating the RSM‐predicted delamination ratio with measured surface roughness, axial force, and material removal rate into gray relational analysis using an L16 orthogonal array ( n = 5000–8000 r/min). A Monte Carlo simulation ( N = 10,000) confirmed 98.2% ranking stability. A confirmation experiment at the recommended optimum ( n = 8000 r/min, ng = 50 r/min, ap = 0.10 mm/r) yielded a gray relational grade of 0.7816, exceeding the L16 best, and the measured delamination ratio closely matched the RSM prediction (error = 3.0%), validating the nested strategy.