MECHANICAL & APPLIED SCIENCE DOMAIN
Published December 2, 2023 | Version v1
Journal article Open

Predictive Modeling and Optimization of Surface Roughness and Cutting Zone Temperature in Turning of Hardened Steel Using RSM, ANN, Genetic Algorithm, and Particle Swarm Optimization

Creators

Description

The purpose of this research is to establish a combined surface roughness and cutting zone temperature study for modeling and optimizing cutting parameters for turning operations of D3/1.2080 steel with coated carbide under cryogenic cooling and MQL conditions. Cutting speed, feed, and depth of cut are investigated as input factors, while surface roughness and cutting zone temperature are chosen as responses. The experiment has been conducted using the Box-Behnken design (BBD) with three levels and three parameters. Response surface methodology (RSM) and Artificial neural network (ANN) techniques are used for modeling to perform prediction. Where ANN outclassed RSM. Then RSM is coupled with Genetic algorithm (GA) and Particle swarm optimization (PSO). RSM-GA and RSM-PSO approaches are used for optimization. It has been discovered that combining RSM with PSO yields superior outcomes. Finally, a comparison between cryogenic cooling and MQL is done. MQL showed supremacy over cryogenic for both responses.

Files

Predictive Modeling and Optimization of Surface Roughness.pdf

Files (572.1 kB)

Additional details

References

  • Jerold, B. D., & Kumar, M. P. (2013). The influence of cryogenic coolants in machining of Ti–6Al–4V. Journal of manufacturing science and engineering, 135(3), 031005. https://doi.org/10.1115/1.4024058.
  • Yildiz, Y., & Nalbant, M. (2008). A review of cryogenic cooling in machining processes. International Journal of Machine Tools and Manufacture, 48(9), 947-964. https://doi.org/10.1016/j.ijmachtools.2008.01.008
  • Leadebal Jr, W. V., de Melo, A. C. A., de Oliveira, A. J., & Castro, N. A. (2018). Effects of cryogenic cooling on the surface integrity in hard turning of AISI D6 steel. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 40, 1-14. https://doi.org/10.1007/s40430-017-0922-6.
  • Yap, T. C. (2019). Roles of cryogenic cooling in turning of superalloys, ferrous metals, and viscoelastic polymers. Technologies, 7(3), 63. https://doi.org/10.3390/technologies7030063.
  • Tawakoli, T., Hadad, M. J., Sadeghi, M. H., Daneshi, A., Stöckert, S., & Rasifard, A. (2009). An experimental investigation of the effects of workpiece and grinding parameters on minimum quantity lubrication—MQL grinding. International Journal of Machine Tools and Manufacture, 49(12-13), 924-932. https://doi.org/10.1016/j.ijmachtools.2009.06.015.
  • Dhar, N. R., Kamruzzaman, M., & Ahmed, M. (2006). Effect of minimum quantity lubrication (MQL) on tool wear and surface roughness in turning AISI-4340 steel. Journal of materials processing technology, 172(2), 299-304. https://doi.org/10.1016/j.jmatprotec.2005.09.022.
  • Da Silva, L. R., Bianchi, E. C., Fusse, R. Y., Catai, R. E., Franca, T. V., & Aguiar, P. R. (2007). Analysis of surface integrity for minimum quantity lubricant—MQL in grinding. International Journal of Machine Tools and Manufacture, 47(2), 412-418. https://doi.org/10.1016/j.ijmachtools.2006.03.015
  • Haron, C. C., Ginting, A., & Goh, J. H. (2001). Wear of coated and uncoated carbides in turning tool steel. Journal of materials processing technology, 116(1), 49-54.
  • Sharif, S., & Rahim, E. A. (2007). Performance of coated-and uncoated-carbide tools when drilling titanium alloy—Ti–6Al4V. Journal of materials processing technology, 185(1-3), 72-76. https://doi.org/10.1016/j.jmatprotec.2006.03.142
  • Kumar, R., Sahoo, A. K., Mishra, P. C., & Das, R. K. (2018). Comparative investigation towards machinability improvement in hard turning using coated and uncoated carbide inserts: part I experimental investigation. Advances in Manufacturing, 6, 52-70. https://doi.org/10.1007/s40436-018-0215-z.