A process prediction model based on cuckoo algorithm for abrasive waterjet machining

Cuckoo is a new evolutionary algorithm which is inspired by lifestyle of bird family. This study proposes Cuckoo algorithm for prediction of the surface roughness of Abrasive Water Jet (AWJ). Several prediction models with different initial eggs were developed and analyzed to investigate the best predicted surface roughness value. The paired sample t-test was used to demonstrate the validity of the results. Throughout this study, it was evidence that the Cuckoo algorithm could improve machining performances of the AWJ. The result shows that the more initial eggs were considered, a much lower predicted value of surface roughness was obtained. When the initial eggs increase, the value of the best parameters become nearer to the goal point. It was found that Cuckoo algorithm is capable for giving an improved surface roughness as it outperformed the results of two established computational techniques, artificial neural network and support vector machine

Modeling and optimization of electric discharge machining performances using harmony search algorithm

Electric Discharge Machining (EDM) is one of the widely used non-conventional machining processes for complex and difficult-to-machine materials. EDM technology has been improve significantly and has been developed in many ideas especially in the manufacturing industries that yielded enormous benefits in economic as well as generating keen interest in research area. A major issue in EDM process is how to obtain accurate results of the machining performance measurement value at optimal point of cutting conditions. Thus, this study proposed harmony search algorithm approach for optimization of surface roughness (Ra) in die sinking electric discharge machining (EDM). The mathematical model was developed using regression analysis based on four machining parameters which are pulse on time, peak current, servo voltage and servo speed. The result shows that the optimal solutions for Ra can be found with the minimum values of 1.3031 μm

Intelligent Modeling and Multi-Response Optimization of AWJC on Fiber Intermetallic Laminates through a Hybrid ANFIS-Salp Swarm Algorithm

The attainment of intricate part profiles for composite laminates for end-use applications is one of the tedious tasks carried out through conventional machining processes. Therefore, the present work emphasized hybrid intelligent modeling and multi-response optimization of abrasive waterjet cutting (AWJC) of a novel fiber intermetallic laminate (FIL) fabricated through carbon/aramid fiber, reinforced with varying wt% of reduced graphene oxide (r-GO) filled epoxy resin and Nitinol shape memory alloy as the skin material. The AWJC experiments were performed by varying the wt% of r-GO (0, 1, and 2%), traverse speed (400, 500, and 600 mm/min), waterjet pressure (200, 250, and 300 MPa), and stand-off distance (2, 3, and 4 mm) as the input parameters, whereas kerf taper (Kt) and surface roughness (Ra) were considered as the quality responses. A hybrid approach of a parametric optimized adaptive neuro-fuzzy inference system (ANFIS) was adopted through three different metaheuristic algorithms such as particle swarm optimization, moth flame optimization, and dragonfly optimization. The prediction efficiency of the ANFIS network has been found to be significantly improved through the moth flame optimization algorithms in terms of minimized prediction errors, such as mean absolute percentage error and root mean square error. Further, multi-response optimization has been performed for optimized ANFIS response models through the salp swarm optimization (SSO) algorithm to identify the optimal AWJC parameters. The optimal set of parameters, such as 1.004 wt% of r-GO, 600 mm/min of traverse speed, 214 MPa of waterjet pressure, and 4 mm of stand-off distance, were obtained for improved quality characteristics. Moreover, the confirmation experiment results show that an average prediction error of 3.38% for Kt and 3.77% for Ra, respectively, were obtained for SSO, which demonstrates the prediction capability of the proposed optimization algorithm

Multi-objective Optimisation in Abrasive Waterjet Contour Cutting of AISI 304L

The optimum waterjet machining parameters were found for maximising material removal rate and minimising surface roughness and kerf taper angle where three levels of traverse speed, abrasive flow rate, and waterjet pressure are used. The multi-linear regression equations were obtained to investigate the relationships between variables and responses, and the statistical significance of contour cutting parameters was analysed using the analysis of variance (ANOVA). Further, the response surface methodology (desirability function approach) was utilised for multi-objective optimisation. The optimum traverse speeds were 95 mm/min for 4 mm thickness and 90 mm/min for both 8 and 12 mm thicknesses. For all material thicknesses, the abrasive mass flow rate and waterjet pressure were 500 g/min and 200 MPa, respectively. The minimum values of surface roughness, kerf taper angle, and maximum material removal rate for 4-, 8- and 12-mm material thicknesses were respectively 0.799º, 1.283 μm and 297.98 mm3/min; 1.068º, 1.694 μm and 514.97 mm3/min; and 1.448º, 1.975 μm and 667.07 mm3/min. In this study, surface roughness and kerf taper angle decreased as the waterjet pressure and abrasive mass flow rate increased; and this is showing a direct proportional relationship with traverse speed, abrasive mass flow rate and waterjet pressure

New insights into the methods for predicting ground surface roughness in the age of digitalisation

Grinding is a multi-length scale material removal process that is widely employed to machine a wide variety of materials in almost every industrial sector. Surface roughness induced by a grinding operation can affect corrosion resistance, wear resistance, and contact stiffness of the ground components. Prediction of surface roughness is useful for describing the quality of ground surfaces, evaluate the efficiency of the grinding process and guide the feedback control of the grinding parameters in real-time to help reduce the cost of production. This paper reviews extant research and discusses advances in the realm of machining theory, experimental design and Artificial Intelligence related to ground surface roughness prediction. The advantages and disadvantages of various grinding methods, current challenges and evolving future trends considering Industry-4.0 ready new generation machine tools are also discussed

Applications of optimization techniques for parametric analysis of non-traditional machining processes: A Review

The constrained applications of conventional machining processes in generating complex shape ge-ometries with the desired degree of tolerance and surface finish in various advanced engineering materials are being gradually compensated by the non-traditional machining (NTM) processes. These NTM processes usually have higher procurement, maintenance, operating and tooling cost. Hence, in order to attain their maximum machining performance, they are usually operated at their optimal or near optimal parametric settings which can easily be determined by the application of dif-ferent optimization techniques. In this paper, 133 international research papers published during 2012-16 on parametric optimization of NTM processes are extensively reviewed to have an idea on the selected process parameters, observed responses, work materials machined and optimization techniques employed in those processes while generating varying part geometries for their industrial use. It is observed that electro discharge machining is the mostly employed NTM process, applied voltage is the identified process parameter with maximum importance, surface roughness and material removal rate are the two maximally preferred responses, different steel grades are the mostly machined work materials and grey relational analysis is the most popular tool utilized for para-metric optimization of NTM processes. These observations would help the process engineers to attain the machining performance of the NTM processes at their fullest extents for different work material and shape feature combinations

Experimental Investigations on Machining of CFRP Composites: Study of Parametric Influence and Machining Performance Optimization

Carbon Fiber Reinforced Polymer (CFRP) composites are characterized by their excellent mechanical properties (high specific strength and stiffness, light weight, high damping capacity etc.) as compared to conventional metals, which results in their increased utilization especially for aircraft and aerospace applications, automotive, defense as well as sporting industries. With increasing applications of CFRP composites, determining economical techniques of production is very important. However, as compared to conventional metals, machining behavior of composites is somewhat different. This is mainly because these materials behave extremely abrasive during machining operations. Machining of CFRP appears difficult due to their material discontinuity, inhomogeneity and anisotropic nature. Moreover, the machining behavior of composites largely depends on the fiber form, the fiber content, fiber orientations of composites and the variability of matrix material. Difficulties are faced during machining of composites due to occurrence of various modes of damages like fiber breakage, matrix cracking, fiber–matrix debonding and delamination. Hence, adequate knowledge and in-depth understanding of the process behavior is indeed necessary to identify the most favorable machining environment in view of various requirements of process performance yields. In this context, present work attempts to investigate aspects of machining performance optimization during machining (turning and drilling) of CFRP composites. In case of turning experiments, the following parameters viz. cutting force, Material Removal Rate (MRR), roughness average (Ra) and maximum tool-tip temperature generated during machining have been considered as process output responses. In case of drilling, the following process performance features viz. load (thrust), torque, roughness average (of the drilled hole) and delamination factor (entry and exit both) have been considered. Attempt has been made to determine the optimal machining parameters setting that can simultaneously satisfy aforesaid response features up to the desired extent. Using Fuzzy Inference System (FIS), multiple response features have been aggregated to obtain an equivalent single performance index called Multi-Performance Characteristic Index (MPCI). A nonlinear regression model has been established in which MPCI has been represented as a function of the machining parameters under consideration. The aforesaid regression model has been considered as the fitness function, and finally optimized by evolutionary algorithms like Harmony Search (HS), Teaching-Learning Based Optimization (TLBO), and Imperialist Competitive Algorithm (ICA) etc. However, the limitation of these algorithms is that they assume a continuous search within parametric domain. These algorithms can give global optima; but the predicted optimal setting may not be possible to adjust in the machine/setup. Since, in most of the machines/setups, provision is given only to adjust factors (process input parameters) at some discrete levels. On the contrary, Taguchi method is based on discrete search philosophy in which predicted optimal setting can easily be achieved in reality.However, Taguchi method fails to solve multi-response optimization problems. Another important aspect that comes into picture while dealing with multi-response optimization problems is the existence of response correlation. Existing Taguchi based integrated optimization approaches (grey-Taguchi, utility-Taguchi, desirability function based Taguchi, TOPSIS, MOORA etc.) may provide erroneous outcome unless response correlation is eliminated. To get rid of that, the present work proposes a PCA-FuzzyTaguchi integrated optimization approach for correlated multi-response optimization in the context of machining CFRP composites. Application potential of aforementioned approach has been compared over various evolutionary algorithms

Algorithms and Methods for Designing and Scheduling Smart Manufacturing Systems

This book, as a Special Issue, is a collection of some of the latest advancements in designing and scheduling smart manufacturing systems. The smart manufacturing concept is undoubtedly considered a paradigm shift in manufacturing technology. This conception is part of the Industry 4.0 strategy, or equivalent national policies, and brings new challenges and opportunities for the companies that are facing tough global competition. Industry 4.0 should not only be perceived as one of many possible strategies for manufacturing companies, but also as an important practice within organizations. The main focus of Industry 4.0 implementation is to combine production, information technology, and the internet. The presented Special Issue consists of ten research papers presenting the latest works in the field. The papers include various topics, which can be divided into three categories—(i) designing and scheduling manufacturing systems (seven articles), (ii) machining process optimization (two articles), (iii) digital insurance platforms (one article). Most of the mentioned research problems are solved in these articles by using genetic algorithms, the harmony search algorithm, the hybrid bat algorithm, the combined whale optimization algorithm, and other optimization and decision-making methods. The above-mentioned groups of articles are briefly described in this order in this book

Enhancement of bees algorithm for global optimisation

This research focuses on the improvement of the Bees Algorithm, a swarm-based nature-inspired optimisation algorithm that mimics the foraging behaviour of honeybees. The algorithm consists of exploitation and exploration, the two key elements of optimisation techniques that help to find the global optimum in optimisation problems. This thesis presents three new approaches to the Bees Algorithm in a pursuit to improve its convergence speed and accuracy. The first proposed algorithm focuses on intensifying the local search area by incorporating Hooke and Jeeves’ method in its exploitation mechanism. This direct search method contains a pattern move that works well in the new variant named “Bees Algorithm with Hooke and Jeeves” (BA-HJ). The second proposed algorithm replaces the randomly generated recruited bees deployment method with chaotic sequences using a well-known logistic map. This new variant called “Bees Algorithm with Chaos” (ChaosBA) was intended to use the characteristic of chaotic sequences to escape from local optima and at the same time maintain the diversity of the population. The third improvement uses the information of the current best solutions to create new candidate solutions probabilistically using the Estimation Distribution Algorithm (EDA) approach. This new version is called Bees Algorithm with Estimation Distribution (BAED). Simulation results show that these proposed algorithms perform better than the standard BA, SPSO2011 and qABC in terms of convergence for the majority of the tested benchmark functions. The BA-HJ outperformed the standard BA in thirteen out of fifteen benchmark functions and is more effective in eleven out of fifteen benchmark functions when compared to SPSO2011 and qABC. In the case of the ChaosBA, the algorithm outperformed the standard BA in twelve out of fifteen benchmark functions and significantly better in eleven out of fifteen test functions compared to qABC and SPSO2011. BAED discovered the optimal solution with the least number of evaluations in fourteen out of fifteen cases compared to the standard BA, and eleven out of fifteen functions compared to SPSO2011 and qABC. Furthermore, the results on a set of constrained mechanical design problems also show that the performance of the proposed algorithms is comparable to those of the standard BA and other swarm-based algorithms from the literature

Artificial cognitive architecture with self-learning and self-optimization capabilities. Case studies in micromachining processes

Tesis doctoral inédita leída en la Universidad Autónoma de Madrid, Escuela Politécnica Superior, Departamento de Ingeniería Informática. Fecha de lectura : 22-09-201