Multi-objective optimisation for minimum quantity lubrication assisted milling process based on hybrid response surface methodology and multi-objective genetic algorithm

© 2019 by SAGE Publications Ltd.Parametric modelling and optimisation play an important role in choosing the best or optimal cutting conditions and parameters during machining to achieve the desirable results. However, analysis of optimisation of minimum quantity lubrication–assisted milling process has not been addressed in detail. Minimum quantity lubrication method is very effective for cost reduction and promotes green machining. Hence, this article focuses on minimum quantity lubrication–assisted milling machining parameters on AISI 1045 material surface roughness and power consumption. A novel low-cost power measurement system is developed to measure the power consumption. A predictive mathematical model is developed for surface roughness and power consumption. The effects of minimum quantity lubrication and machining parameters are examined to determine the optimum conditions with minimum surface roughness and minimum power consumption. Empirical models are developed to predict surface roughness and power of machine tool effectively and accurately using response surface methodology and multi-objective optimisation genetic algorithm. Comparison of results obtained from response surface methodology and multi-objective optimisation genetic algorithm depict that both measured and predicted values have a close agreement. This model could be helpful to select the best combination of end-milling machining parameters to save power consumption and time, consequently, increasing both productivity and profitability.Peer reviewedFinal Published versio

A Survey of Automated Process Planning Approaches in Machining

Global industrial trend is shifting towards next industrial revolution Industry 4.0. It is becoming increasingly important for modern manufacturing industries to develop a Computer Integrated Manufacturing (CIM) system by integrating the various operational and information processing functions in design and manufacturing. In spite of being active in research for almost four decades, it is clear that new functionalities are needed to integrate and realize a completely optimal process planning which can be fully compliant towards Smart Factory. In order to develop a CIM system, Computer Aided Process Planning (CAPP) plays a key role and therefore it has been the focus of many researchers. In order to gain insight into the current state-of-the-art of CAPP methodologies, 96 research papers have been reviewed. Subsequent sections discuss the different CAPP approaches adopted by researchers to automate different process planning tasks. This paper aims at addressing the key approaches involved and future directions towards Smart Manufacturing

From computer-aided to intelligent machining: Recent advances in computer numerical control machining research

The aim of this paper is to provide an introduction and overview of recent advances in the key technologies and the supporting computerized systems, and to indicate the trend of research and development in the area of computational numerical control machining. Three main themes of recent research in CNC machining are simulation, optimization and automation, which form the key aspects of intelligent manufacturing in the digital and knowledge based manufacturing era. As the information and knowledge carrier, feature is the efficacious way to achieve intelligent manufacturing. From the regular shaped feature to freeform surface feature, the feature technology has been used in manufacturing of complex parts, such as aircraft structural parts. The authors’ latest research in intelligent machining is presented through a new concept of multi-perspective dynamic feature (MpDF), for future discussion and communication with readers of this special issue. The MpDF concept has been implemented and tested in real examples from the aerospace industry, and has the potential to make promising impact on the future research in the new paradigm of intelligent machining. The authors of this paper are the guest editors of this special issue on computational numerical control machining. The guest editors have extensive and complementary experiences in both academia and industry, gained in China, USA and UK

Determination of Cost-Effective Range in Surface Finish for Single Pass Turning

Surface finish is considered a critical characteristic for manufacturing components when manufacturers strive to produce components with high-quality characteristics predefined by design engineers. The objective of this research is to provide a cost-effective range in surface finish for single pass turning that enables the design engineers to explore a wider spectrum of alternative solutions without significantly affecting the functionality of the part. Apart from the one optimal solution, the proposed methodology, which is based on Geometric Programming, would provide a range of cutting conditions solutions that satisfy the economic and functional needs for the designer. This can be achieved by switching cost reduction focus from tooling to labor cost, particularly by adjusting variables values such as spindle speed and feed. An algorithm has been developed to find the new variables values. In addition, a sensitivity analysis model, based on metaheuristic techniques, will also be developed to further give a set of possible solutions that are practically preferable to the practitioners. In addition, the developed methodology can be applied to other engineering applications. The proposed methodology will provide a tool that enhances the design for manufacturability for companies to become more competitive