From single-point to range optimization: A novel approach for determining robust polishing parameters of TC17 alloy blades

To enhance the efficiency and robustness of flexible polishing for aeroengine blades, this study proposes a coupling-effect-based optimization algorithm to determine optimal process parameter ranges. Using Central Composite Design (CCD), quadratic response surface models were developed to correlate surface roughness (R_a) and residual stress with spindle speed (n), compression depth (a_p), feed speed (v_w), and abrasive mesh number (M). ANOVA confirmed the models’ statistical significance and superior goodness-of-fit. A Multi-Objective Genetic Algorithm (MOGA) was then employed to derive the Pareto optimal set, identifying parameters that satisfy engineering requirements (R_a < 0.4 μm) while minimizing residual stress. Based on response surface-based tolerance analysis, the optimal operational windows were established: spindle speed n ∈ [6773.6, 8000] r/min, compression depth a_p ∈ [1.016, 1.6] mm, feed speed v_w ∈ [100, 268.6356] mm/min, and abrasive mesh number M ∈ [496.4032, 800] #. Unlike conventional single-point estimates, this approach provides practical operational windows that significantly improve production efficiency and process robustness for flexible polishing applications.