A cuckoo search optimisation-based Grey prediction model for thermal error compensation on CNC machine tools

Purpose The purpose of this paper is to produce an intelligent technique for modelling machine tool errors caused by the thermal distortion of Computer Numerical Control (CNC) machine tools. A new metaheuristic method, the cuckoo search (CS) algorithm, based on the life of a bird family is proposed to optimize the GMC(1, N) coefficients. It is then used to predict thermal error on a small vertical milling centre based on selected sensors. Design/methodology/approach A Grey model with convolution integral GMC(1, N) is used to design a thermal prediction model. To enhance the accuracy of the proposed model, the generation coefficients of GMC(1, N) are optimized using a new metaheuristic method, called the CS algorithm. Findings The results demonstrate good agreement between the experimental and predicted thermal error. It can therefore be concluded that it is possible to optimize a Grey model using the CS algorithm, which can be used to predict the thermal error of a CNC machine tool. Originality/value An attempt has been made for the first time to apply CS algorithm for calibrating the GMC(1, N) model. The proposed CS-based Grey model has been validated and compared with particle swarm optimization (PSO) based Grey model. Simulations and comparison show that the CS algorithm outperforms PSO and can act as an alternative optmization algorithm for Grey models that can be used for thermal error compensation

Parametric Optimization of Taper Cutting Process using Wire Electrical Discharge Machining (WEDM)

Significant technological advancement of wire electrical discharge machining (WEDM) process has been observed in recent times in order to meet the requirements of various manufacturing fields especially in the production of parts with complex geometry in precision die industry. Taper cutting is an important application of WEDM process aiming at generating complex parts with tapered profiles. Wire deformation and breakage are more pronounced in taper cutting as compared with straight cutting resulting in adverse effect on desired taper angle and surface integrity. The reasons for associated problems may be attributed to certain stiffness of the wire. However, controlling the process parameters can somewhat reduce these problems. Extensive literature review reveals that effect of process parameters on various performance measures in taper cutting using WEDM is also not adequately addressed. Hence, study on effect of process parameters on performance measures using various advanced metals and metal matrix composites (MMC) has become the predominant research area in this field. In this context, the present work attempts to experimentally investigate the machining performance of various alloys, super alloys and metal matrix composite during taper cutting using WEDM process. The effect of process parameters such as part thickness, taper angle, pulse duration, discharge current, wire speed and wire tension on various performance measures such as angular error, surface roughness, cutting rate and white layer thickness are studied using Taguchi’s analysis. The functional relationship between the input parameters and performance measures has been developed by using non-linear regression analysis. Simultaneous optimization of the performance measures has been carried out using latest nature inspired algorithms such as multi-objective particle swarm optimization (MOPSO) and bat algorithm. Although MOPSO develops a set of non-dominated solutions, the best ranked solution is identified from a large number of solutions through application of maximum deviation method rather than resorting to human judgement. Deep cryogenic treatment of both wire and work material has been carried out to enhance the machining efficiency of the low conductive work material like Inconel 718. Finally, artificial intelligent models are proposed to predict the various performance measures prior to machining. The study offers useful insight into controlling the parameters to improve the machining efficiency

Parametric Optimization of Taper Cutting Process using Wire Electrical Discharge Machining (WEDM)

Significant technological advancement of wire electrical discharge machining (WEDM) process has been observed in recent times in order to meet the requirements of various manufacturing fields especially in the production of parts with complex geometry in precision die industry. Taper cutting is an important application of WEDM process aiming at generating complex parts with tapered profiles. Wire deformation and breakage are more pronounced in taper cutting as compared with straight cutting resulting in adverse effect on desired taper angle and surface integrity. The reasons for associated problems may be attributed to certain stiffness of the wire. However, controlling the process parameters can somewhat reduce these problems. Extensive literature review reveals that effect of process parameters on various performance measures in taper cutting using WEDM is also not adequately addressed. Hence, study on effect of process parameters on performance measures using various advanced metals and metal matrix composites (MMC) has become the predominant research area in this field. In this context, the present work attempts to experimentally investigate the machining performance of various alloys, super alloys and metal matrix composite during taper cutting using WEDM process. The effect of process parameters such as part thickness, taper angle, pulse duration, discharge current, wire speed and wire tension on various performance measures such as angular error, surface roughness, cutting rate and white layer thickness are studied using Taguchi’s analysis. The functional relationship between the input parameters and performance measures has been developed by using non-linear regression analysis. Simultaneous optimization of the performance measures has been carried out using latest nature inspired algorithms such as multi-objective particle swarm optimization (MOPSO) and bat algorithm. Although MOPSO develops a set of non-dominated solutions, the best ranked solution is identified from a large number of solutions through application of maximum deviation method rather than resorting to human judgement. Deep cryogenic treatment of both wire and work material has been carried out to enhance the machining efficiency of the low conductive work material like Inconel 718. Finally, artificial intelligent models are proposed to predict the various performance measures prior to machining. The study offers useful insight into controlling the parameters to improve the machining efficiency

Green Technologies for Production Processes

This book focuses on original research works about Green Technologies for Production Processes, including discrete production processes and process production processes, from various aspects that tackle product, process, and system issues in production. The aim is to report the state-of-the-art on relevant research topics and highlight the barriers, challenges, and opportunities we are facing. This book includes 22 research papers and involves energy-saving and waste reduction in production processes, design and manufacturing of green products, low carbon manufacturing and remanufacturing, management and policy for sustainable production, technologies of mitigating CO2 emissions, and other green technologies

Cellular Metals: Fabrication, Properties and Applications

Cellular solids and porous metals have become some of the most promising lightweight multifunctional materials due to their superior combination of advanced properties mainly derived from their base material and cellular structure. They are used in a wide range of commercial, biomedical, industrial, and military applications. In contrast to other cellular materials, cellular metals are non-flammable, recyclable, extremely tough, and chemically stable and are excellent energy absorbers. The manuscripts of this Special Issue provide a representative insight into the recent developments in this field, covering topics related to manufacturing, characterization, properties, specific challenges in transportation, and the description of structural features. For example, a presented strategy for the strengthening of Al-alloy foams is the addition of alloying elements (e.g., magnesium) into the metal bulk matrix to promote the formation of intermetallics (e.g., precipitation hardening). The incorporation of micro-sized and nano-sized reinforcement elements (e.g., carbon nanotubes and graphene oxide) into the metal bulk matrix to enhance the performance of the ductile metal is presented. New bioinspired cellular materials, such as nanocomposite foams, lattice materials, and hybrid foams and structures are also discussed (e.g., filled hollow structures, metal-polymer hybrid cellular structures)

Evolutionary Algorithms in Engineering Design Optimization

Evolutionary algorithms (EAs) are population-based global optimizers, which, due to their characteristics, have allowed us to solve, in a straightforward way, many real world optimization problems in the last three decades, particularly in engineering fields. Their main advantages are the following: they do not require any requisite to the objective/fitness evaluation function (continuity, derivability, convexity, etc.); they are not limited by the appearance of discrete and/or mixed variables or by the requirement of uncertainty quantification in the search. Moreover, they can deal with more than one objective function simultaneously through the use of evolutionary multi-objective optimization algorithms. This set of advantages, and the continuously increased computing capability of modern computers, has enhanced their application in research and industry. From the application point of view, in this Special Issue, all engineering fields are welcomed, such as aerospace and aeronautical, biomedical, civil, chemical and materials science, electronic and telecommunications, energy and electrical, manufacturing, logistics and transportation, mechanical, naval architecture, reliability, robotics, structural, etc. Within the EA field, the integration of innovative and improvement aspects in the algorithms for solving real world engineering design problems, in the abovementioned application fields, are welcomed and encouraged, such as the following: parallel EAs, surrogate modelling, hybridization with other optimization techniques, multi-objective and many-objective optimization, etc

Bioinspired metaheuristic algorithms for global optimization

This paper presents concise comparison study of newly developed bioinspired algorithms for global optimization problems. Three different metaheuristic techniques, namely Accelerated Particle Swarm Optimization (APSO), Firefly Algorithm (FA), and Grey Wolf Optimizer (GWO) are investigated and implemented in Matlab environment. These methods are compared on four unimodal and multimodal nonlinear functions in order to find global optimum values. Computational results indicate that GWO outperforms other intelligent techniques, and that all aforementioned algorithms can be successfully used for optimization of continuous functions

Experimental Evaluation of Growing and Pruning Hyper Basis Function Neural Networks Trained with Extended Information Filter

In this paper we test Extended Information Filter (EIF) for sequential training of Hyper Basis Function Neural Networks with growing and pruning ability (HBF-GP). The HBF neuron allows different scaling of input dimensions to provide better generalization property when dealing with complex nonlinear problems in engineering practice. The main intuition behind HBF is in generalization of Gaussian type of neuron that applies Mahalanobis-like distance as a distance metrics between input training sample and prototype vector. We exploit concept of neuron’s significance and allow growing and pruning of HBF neurons during sequential learning process. From engineer’s perspective, EIF is attractive for training of neural networks because it allows a designer to have scarce initial knowledge of the system/problem. Extensive experimental study shows that HBF neural network trained with EIF achieves same prediction error and compactness of network topology when compared to EKF, but without the need to know initial state uncertainty, which is its main advantage over EKF

Uncertain Multi-Criteria Optimization Problems

Most real-world search and optimization problems naturally involve multiple criteria as objectives. Generally, symmetry, asymmetry, and anti-symmetry are basic characteristics of binary relationships used when modeling optimization problems. Moreover, the notion of symmetry has appeared in many articles about uncertainty theories that are employed in multi-criteria problems. Different solutions may produce trade-offs (conflicting scenarios) among different objectives. A better solution with respect to one objective may compromise other objectives. There are various factors that need to be considered to address the problems in multidisciplinary research, which is critical for the overall sustainability of human development and activity. In this regard, in recent decades, decision-making theory has been the subject of intense research activities due to its wide applications in different areas. The decision-making theory approach has become an important means to provide real-time solutions to uncertainty problems. Theories such as probability theory, fuzzy set theory, type-2 fuzzy set theory, rough set, and uncertainty theory, available in the existing literature, deal with such uncertainties. Nevertheless, the uncertain multi-criteria characteristics in such problems have not yet been explored in depth, and there is much left to be achieved in this direction. Hence, different mathematical models of real-life multi-criteria optimization problems can be developed in various uncertain frameworks with special emphasis on optimization problems