Anggoro P W, Bawono B, Jamari J, Tauviqirrahman M, Bayuseno A P
Department of Industrial Engineering, Faculty of Industrial Technology, University of Atma Jaya Yogyakarta, Jl. Babarsari 44, Yogyakarta 55281, Indonesia.
Department of Mechanical Engineering, University of Diponegoro, Jl. Prof. Soedarto, SH., Tembalang, Semarang 50275, Indonesia.
Heliyon. 2021 Mar 15;7(3):e06481. doi: 10.1016/j.heliyon.2021.e06481. eCollection 2021 Mar.
Herein, a machining strategy to fabricate custom orthotic insoles with high surface finish and wide fit tolerance is presented. CNC milling was used to machine ethylene-vinyl acetate (EVA) foam for insoles with various surface hardness, and the Taguchi-response surface method (TM-RSM) was adopted to optimize the parameters of the CNC milling process (cutting speed, feed rate, tool path strategy, and step over). EVA foam with varying surface hardness and the tolerance of the wide fit insoles corresponding to the surface roughness were analyzed. Subsequently, a mathematical model was established to determine the optimal CNC milling parameters for a standard milling cutter under dry coolants. The results of the six parameters corresponding to the mean values of surface roughness were initially examined using the signal-to-noise ratio of the Taguchi method (TM). The surface roughness obtained with the TM-RSM was up to 4.13% higher than that obtained with the TM. The EVA foam insole with a surface hardness of 50-60 HRC and a wide fit tolerance of 0.75 mm provided the ideal level of comfort and support for patients with diabetes. The results of this study demonstrated that CNC milling provided a better surface finish of orthotic shoe insoles than other methods, which can serve as guidance in the development of machining strategies for insoles made from EVA foam.
本文提出了一种制造具有高表面光洁度和宽适配公差的定制矫形鞋垫的加工策略。采用数控铣削加工具有不同表面硬度的乙烯-醋酸乙烯酯（EVA）泡沫鞋垫，并采用田口-响应面法（TM-RSM）优化数控铣削工艺参数（切削速度、进给速度、刀具路径策略和步距）。分析了具有不同表面硬度的EVA泡沫以及与表面粗糙度相对应的宽适配鞋垫的公差。随后，建立了一个数学模型，以确定在干式冷却液条件下标准铣刀的最佳数控铣削参数。首先使用田口方法（TM）的信噪比检验了与表面粗糙度平均值相对应的六个参数的结果。使用TM-RSM获得的表面粗糙度比使用TM获得的表面粗糙度高出4.13%。表面硬度为50-60 HRC且宽适配公差为0.75 mm的EVA泡沫鞋垫为糖尿病患者提供了理想的舒适度和支撑度。本研究结果表明，数控铣削比其他方法能提供更好的矫形鞋垫表面光洁度，可为EVA泡沫鞋垫加工策略的制定提供指导。
