An intelligent approach for multi-response optimization: a case study of non-traditional machining process

The present work proposes an intelligent approach to solve multi-response optimization problem in electrical discharge machining of AISI D2 using response surface methodology (RSM) combined with optimization techniques. Four process parameters (factors) such as discharge current (Ip), pulse-on-time (Ton), duty factor (τ) and flushing pressure (Fp) and four important responses like material removal rate (MRR), tool wear rate (TWR), surface roughness (Ra) and circularity (r1/r2) of machined component are considered in this study. A Box-Behnken RSM design is used to collect experimental data and develop empirical models relating input parameters and responses. Genetic algorithm (GA), an efficient search technique, is used to obtain the optimal setting for desired responses. It is to be noted that there is no single optimal setting which will produce best performance satisfying all the responses. In industries, to solve such problems, managers frequently depend on their past experience and judgement. Human intervention causes uncertainties present in the decision making process gleaned into solution methodology resulting in inferior solutions. Fuzzy inference system has been a viable option to address multiple response problems considering uncertainties and impreciseness caused during judgement process and experimental data collection. However, choosing right kind of membership functions and development of fuzzy rule base happen to be cumbersome job for the managers. To address this issue, a methodology based on combined neuro-fuzzy system and particle swarm optimization (PSO) is adopted to optimize multiple responses simultaneously. To avoid the conflicting nature of responses, they are first converted to signal-to-noise (S/N) ratio and then normalized. The proposed neuro-fuzzy approach is used to convert the responses into a single equivalent response known as Multi-response Performance Characteristic Index (MPCI). The effect of parameters on MPCI values has been studied in detail and a process model has been developed. Finally, optimal parameter setting is obtained by particle swarm optimization technique. The optimal setting so generated that satisfy all the responses may not be the best one due to aggregation of responses into a single response during neuro-fuzzy stage. In this direction, a multi-objective optimization based on non-dominated sorting genetic algorithm (NSGA) has been adopted to optimize the responses such that a set of mutually dominant solutions are found over a wide range of machining parameters. The proposed optimal settings are validated using thermal-modeling of finite element analysis

A Comprehensive Survey on Particle Swarm Optimization Algorithm and Its Applications

Particle swarm optimization (PSO) is a heuristic global optimization method, proposed originally by Kennedy and Eberhart in 1995. It is now one of the most commonly used optimization techniques. This survey presented a comprehensive investigation of PSO. On one hand, we provided advances with PSO, including its modifications (including quantum-behaved PSO, bare-bones PSO, chaotic PSO, and fuzzy PSO), population topology (as fully connected, von Neumann, ring, star, random, etc.), hybridization (with genetic algorithm, simulated annealing, Tabu search, artificial immune system, ant colony algorithm, artificial bee colony, differential evolution, harmonic search, and biogeography-based optimization), extensions (to multiobjective, constrained, discrete, and binary optimization), theoretical analysis (parameter selection and tuning, and convergence analysis), and parallel implementation (in multicore, multiprocessor, GPU, and cloud computing forms). On the other hand, we offered a survey on applications of PSO to the following eight fields: electrical and electronic engineering, automation control systems, communication theory, operations research, mechanical engineering, fuel and energy, medicine, chemistry, and biology. It is hoped that this survey would be beneficial for the researchers studying PSO algorithms

Intelligent Machine Learning: Tailor-Making Macromolecules

Nowadays, polymer reaction engineers seek robust and effective tools to synthesize complex macromolecules with well-defined and desirable microstructural and architectural characteristics. Over the past few decades, several promising approaches, such as controlled living (co)polymerization systems and chain-shuttling reactions have been proposed and widely applied to synthesize rather complex macromolecules with controlled monomer sequences. Despite the unique potential of the newly developed techniques, tailor-making the microstructure of macromolecules by suggesting the most appropriate polymerization recipe still remains a very challenging task. In the current work, two versatile and powerful tools capable of effectively addressing the aforementioned questions have been proposed and successfully put into practice. The two tools are established through the amalgamation of the Kinetic Monte Carlo simulation approach and machine learning techniques. The former, an intelligent modeling tool, is able to model and visualize the intricate inter-relationships of polymerization recipes/conditions (as input variables) and microstructural features of the produced macromolecules (as responses). The latter is capable of precisely predicting optimal copolymerization conditions to simultaneously satisfy all predefined microstructural features. The effectiveness of the proposed intelligent modeling and optimization techniques for solving this extremely important ‘inverse’ engineering problem was successfully examined by investigating the possibility of tailor-making the microstructure of Olefin Block Copolymers via chain-shuttling coordination polymerization

Study on Parametric Optimization of Fused Deposition Modelling (FDM) Process

Rapid prototyping (RP) is a generic term for a number of technologies that enable fabrication of physical objects directly from CAD data sources. In contrast to classical methods of manufacturing such as milling and forging which are based on subtractive and formative principles espectively, these processes are based on additive principle for part fabrication. The biggest advantage of RP processes is that an entire 3-D (three-dimensional) consolidated assembly can be fabricated in a single setup without any tooling or human intervention; further, the part fabrication methodology is independent of the mplexity of the part geometry. Due to several advantages, RP has attracted the considerable attention of manufacturing industries to meet the customer demands for incorporating continuous and rapid changes in manufacturing in shortest possible time and gain edge over competitors. Out of all commercially available RP processes, fused deposition modelling (FDM) uses heated thermoplastic filament which are extruded from the tip of nozzle in a prescribed manner in a temperature controlled environment for building the part through a layer by layer deposition method. Simplicity of operation together with the ability to fabricate parts with locally controlled properties resulted in its wide spread application not only for prototyping but also for making functional parts. However, FDM process has its own demerits related with accuracy, surface finish, strength etc. Hence, it is absolutely necessary to understand the shortcomings of the process and identify the controllable factors for improvement of part quality. In this direction, present study focuses on the improvement of part build methodology by properly controlling the process parameters. The thesis deals with various part quality measures such as improvement in dimensional accuracy, minimization of surface roughness, and improvement in mechanical properties measured in terms of tensile, compressive, flexural, impact strength and sliding wear. The understanding generated in this work not only explain the complex build mechanism but also present in detail the influence of processing parameters such as layer thickness, orientation, raster angle, raster width and air gap on studied responses with the help of statistically validated models, microphotographs and non-traditional optimization methods. For improving dimensional accuracy of the part, Taguchi‟s experimental design is adopted and it is found that measured dimension is oversized along the thickness direction and undersized along the length, width and diameter of the hole. It is observed that different factors and interactions control the part dimensions along different directions. Shrinkage of semi molten material extruding out from deposition nozzle is the major cause of part dimension reduction. The oversized dimension is attributed to uneven layer surfaces generation and slicing constraints. For recommending optimal factor setting for improving overall dimension of the part, grey Taguchi method is used. Prediction models based on artificial neural network and fuzzy inference principle are also proposed and compared with Taguchi predictive model. The model based on fuzzy inference system shows better prediction capability in comparison to artificial neural network model. In order to minimize the surface roughness, a process improvement strategy through effective control of process parameters based on central composite design (CCD) is employed. Empirical models relating response and process parameters are developed. The validity of the models is established using analysis of variance (ANOVA) and residual analysis. Experimental results indicate that process parameters and their interactions are different for minimization of roughness in different surfaces. The surface roughness responses along three surfaces are combined into a single response known as multi-response performance index (MPI) using principal component analysis. Bacterial foraging optimisation algorithm (BFOA), a latest evolutionary approach, has been adopted to find out best process parameter setting which maximizes MPI. Assessment of process parameters on mechanical properties viz. tensile, flexural, impact and compressive strength of part fabricated using FDM technology is done using CCD. The effect of each process parameter on mechanical property is analyzed. The major reason for weak strength is attributed to distortion within or between the layers. In actual practice, the parts are subjected to various types of loadings and it is necessary that the fabricated part must withhold more than one type of loading simultaneously.To address this issue, all the studied strengths are combined into a single response known as composite desirability and then optimum parameter setting which will maximize composite desirability is determined using quantum behaved particle swarm optimization (QPSO). Resistance to wear is an important consideration for enhancing service life of functional parts. Hence, present work also focuses on extensive study to understand the effect of process parameters on the sliding wear of test specimen. The study not only provides insight into complex dependency of wear on process parameters but also develop a statistically validated predictive equation. The equation can be used by the process planner for accurate wear prediction in practice. Finally, comparative evaluation of two swarm based optimization methods such as QPSO and BFOA are also presented. It is shown that BFOA, because of its biologically motivated structure, has better exploration and exploitation ability but require more time for convergence as compared to QPSO. The methodology adopted in this study is quite general and can be used for other related or allied processes, especially in multi input, multi output systems. The proposed study can be used by industries like aerospace, automobile and medical for identifying the process capability and further improvement in FDM process or developing new processes based on similar principle

Active thermography for the investigation of corrosion in steel surfaces

The present work aims at developing an experimental methodology for the analysis of corrosion phenomena of steel surfaces by means of Active Thermography (AT), in reflexion configuration (RC). The peculiarity of this AT approach consists in exciting by means of a laser source the sound surface of the specimens and acquiring the thermal signal on the same surface, instead of the corroded one: the thermal signal is then composed by the reflection of the thermal wave reflected by the corroded surface. This procedure aims at investigating internal corroded surfaces like in vessels, piping, carters etc. Thermal tests were performed in Step Heating and Lock-In conditions, by varying excitation parameters (power, time, number of pulse, ….) to improve the experimental set up. Surface thermal profiles were acquired by an IR thermocamera and means of salt spray testing; at set time intervals the specimens were investigated by means of AT. Each duration corresponded to a surface damage entity and to a variation in the thermal response. Thermal responses of corroded specimens were related to the corresponding corrosion level, referring to a reference specimen without corrosion. The entity of corrosion was also verified by a metallographic optical microscope to measure the thickness variation of the specimens

Experimental Studies on Machinability of Inconel Super Alloy during Electro-Discharge Machining: Emphasis on Surface Integrity and Metallurgical Characteristics of the EDMed Work Surface

Inconel alloys are Nickel-Chromium based high temperature super alloys widely applied in aerospace, marine, nuclear power generation; chemical, petrochemical and process industries. Execution of traditional machining operations on Inconel super alloy is quite difficult due to its very low thermal conductivity which increases thermal effects during machining operations. Inconel often exhibits strong work hardening behavior, high adhesion characteristics onto the tool face, and thereby alters cutting process parameters to a remarkable extent. Additionally, Inconel may contain hard abrasive particles and carbides that create excessive tool wear; and, hence, surface integrity of the end product appears disappointing. The extent of tool life is substantially reduced. Thus, Inconel super alloys are included in the category of ‘difficult-to-cut’ materials. In view of the difficulties faced during conventional machining, non-traditional machining routes like Electro-Discharge Machining (EDM), Wire Electro-Discharge Machining (WEDM), micro-machining (micro-electro-discharge drilling) etc. are being attempted for processing of Inconel in order to achieve desired contour and intricate geometry of the end product with reasonably good dimensional accuracy. However, low material removal rate and inferior surface integrity seem to be a challenge. In this context, the present dissertation has aimed at investigating machining and machinability aspects of Inconel super alloys (different grades) during electro-discharge machining. Effects of process control parameters (viz. peak discharge current, pulse-on time, gap voltage, duty factor, and flushing pressure) on influencing EDM performance in terms of Material Removal Rate (MRR), Electrode Wear Rate (EWR) and Surface Roughness (SR) of the EDMed Inconel specimens have been examined. Morphology along with topographical features of the EDMed Inconel work surface have been studied in view of severity of surface cracking and extent of white layer depth. Additionally, X-Ray Diffraction (XRD) analysis has been carried out to study metallurgical characteristics of the EDMed work surface of Inconel specimens (viz. phases present and precipitates, extent of grain refinement, crystallite size, and dislocation density etc.) in comparison with that of ‘as received’ parent material. Results, obtained thereof, have been interpreted with relevance to Energy Dispersive X-ray Spectroscopy (EDS) analysis, residual stress and micro-indentation hardness test data. Effort has been made to determine the most appropriate EDM parameters setting to optimize MRR, EWR, along with Ra (roughness average), relative Surface Crack Density (SCD), as well as relative White Layer Thickness (WLT) observed onto the EDMed work surface of Inconel specimens. Moreover, an attempt has been made to examine the ease of electro-discharge machining on Inconel work materials using Deep Cryogenically Treated (DCT) tool/workpiece. A unified attempt has also made to compare surface integrity and metallurgical characteristics of the EDMed Inconel work surface as compared to the EDMed A2 tool steel (SAE 304SS) as well as EDMed Titanium alloy (Ti-6Al-4V)

Principles and Characteristics of Different EDM Processes in Machining Tool and Die Steels

Electric discharge machining (EDM) is one of the most efficient manufacturing technologies used in highly accurate processing of all electrically conductive materials irrespective of their mechanical properties. It is a non-contact thermal energy process applied to a wide range of applications, such as in the aerospace, automotive, tools, molds and dies, and surgical implements, especially for the hard-to-cut materials with simple or complex shapes and geometries. Applications to molds, tools, and dies are among the large-scale initial applications of this process. Machining these items is especially difficult as they are made of hard-to-machine materials, they have very complex shapes of high accuracy, and their surface characteristics are sensitive to machining conditions. The review of this kind with an emphasis on tool and die materials is extremely useful to relevant professions, practitioners, and researchers. This review provides an overview of the studies related to EDM with regard to selection of the process, material, and operating parameters, the effect on responses, various process variants, and new techniques adopted to enhance process performance. This paper reviews research studies on the EDM of different grades of tool steel materials. This article (i) pans out the reported literature in a modular manner with a focus on experimental and theoretical studies aimed at improving process performance, including material removal rate, surface quality, and tool wear rate, among others, (ii) examines evaluation models and techniques used to determine process conditions, and (iii) discusses the developments in EDM and outlines the trends for future research. The conclusion section of the article carves out precise highlights and gaps from each section, thus making the article easy to navigate and extremely useful to the related research communit

Efficient design of post-tensioned concrete box-girder road bridges based on sustainable multi-objective criteria

[EN] Bridges, as an important component of infrastructure, are expected to meet all the requirements for a modern society. Traditionally, the primary aim in bridge design has been to achieve the lowest cost while guaranteeing the structural efficiency. However, concerns regarding building a more sustainable future have change the priorities of society. Ecological and durable structures are increasingly demanded. Under these premises, heuristic optimization methods provide an effective alternative to structural designs based on experience. The emergence of new materials, structural designs and sustainable criteria motivate the need to create a methodology for the automatic and accurate design of a real post-tensioned concrete bridge that considers all these aspects. For the first time, this thesis studies the efficient design of post-tensioned concrete box-girder road bridges from a sustainable point of view. This research integrates environmental, safety and durability criteria into the optimum design of the bridge. The methodology proposed provides multiple trade-off solutions that hardly increase the cost and achieve improved safety and durability. Likewise, this approach quantifies the sustainable criteria in economic terms, and evaluates the effect of these criteria on the best values of the variables. In this context, a multi-objective optimization is formulated to provide multiple trade-off and high-performing solutions that balance economic, ecologic and societal goals. An optimization design program selects the best geometry, concrete type, reinforcement and post-tensioning steel that meet the objectives selected. A three-span continuous box-girder road bridge located in a coastal region is selected for a case study. This approach provides vital knowledge about this type of bridge in the sustainable context. The life-cycle perspective has been included through a lifetime performance evaluation that models the bridge deterioration process due to chloride-induced corrosion. The economic, environmental and societal impacts of maintenance actions required to extend the service life are examined. Therefore, the proposed goals for an efficient design have been switch from initial stage to life-cycle consideration. Faced with the large computational time of multi-objective optimization and finite-element analysis, artificial neural networks (ANNs) are integrated in the proposed methodology. ANNs are trained to predict the structural response based on the design variables, without the need to analyze the bridge response. The multi-objective optimization problem results in a set of trade-off solutions characterized by the presence of conflicting objectives. The final selection of preferred solutions is simplified by a decision-making technique. A rational technique converts a verbal pairwise comparison between criteria with a degree of uncertainty into numerical values that guarantee the consistency of judgments. This thesis gives a guide for the sustainable design of concrete structures. The use of the proposed approach leads to designs with lower life-cycle cost and emissions compared to general design approaches. Both bridge safety and durability can be improved with a little cost increment by choosing the correct design variables. In addition, this methodology is applicable to any type of structure and material.[ES] Los puentes, como parte importante de una infraestructura, se espera que reúnan todos los requisitos de una sociedad moderna. Tradicionalmente, el objetivo principal en el diseño de puentes ha sido lograr el menor coste mientras se garantiza la eficiencia estructural. Sin embargo, la preocupación por construir un futuro más sostenible ha provocado un cambio en las prioridades de la sociedad. Estructuras más ecológicas y duraderas son cada vez más demandadas. Bajo estas premisas, los métodos de optimización heurística proporcionan una alternativa eficaz a los diseños estructurales basados en la experiencia. La aparición de nuevos materiales, diseños estructurales y criterios sostenibles motivan la necesidad de crear una metodología para el diseño automático y preciso de un puente real de hormigón postesado que considere todos estos aspectos. Por primera vez, esta tesis estudia el diseño eficiente de puentes de hormigón postesado con sección en cajón desde un punto de vista sostenible. Esta investigación integra criterios ambientales, de seguridad estructural y durabilidad en el diseño óptimo del puente. La metodología propuesta proporciona múltiples soluciones que apenas encarecen el coste y mejoran la seguridad y durabilidad. Al mismo tiempo, se cuantifica el enfoque sostenible en términos económicos, y se evalúa el efecto que tienen dichos criterios en el valor óptimo de las variables. En este contexto, se formula una optimización multiobjetivo que proporciona soluciones eficientes y de compromiso entre los criterios económicos, ecológicos y sociales. Un programa de optimización del diseño selecciona la mejor combinación de geometría, tipo de hormigón, armadura y postesado que cumpla con los objetivos seleccionados. Se ha escogido como caso de estudio un puente continuo en cajón de tres vanos situado en la costa. Este método proporciona un mayor conocimiento sobre esta tipología de puentes desde un punto de vista sostenible. Se ha estudiado el ciclo de vida a través de la evaluación del deterioro estructural del puente debido al ataque por cloruros. Se examina el impacto económico, ambiental y social que produce el mantenimiento necesario para extender la vida útil del puente. Por lo tanto, los objetivos propuestos para un diseño eficiente han sido trasladados desde la etapa inicial hasta la consideración del ciclo de vida. Para solucionar el problema del elevado tiempo de cálculo debido a la optimización multiobjetivo y el análisis por elementos finitos, se han integrado redes neuronales en la metodología propuesta. Las redes neuronales son entrenadas para predecir la respuesta estructural a partir de las variables de diseño, sin la necesidad de analizar el puente. El problema de optimización multiobjetivo se traduce en un conjunto de soluciones de compromiso que representan objetivos contrapuestos. La selección final de las soluciones preferidas se simplifica mediante una técnica de toma de decisiones. Una técnica estructurada convierte los juicios basados en comparaciones por pares de elementos con un grado de incertidumbre en valores numéricos que garantizan la consistencia de dichos juicios. Esta tesis proporciona una guía que extiende y mejora las recomendaciones sobre el diseño de estructuras de hormigón dentro del contexto de desarrollo sostenible. El uso de la metodología propuesta lleva a diseños con menor coste y emisiones del ciclo de vida, comparado con diseños que siguen metodologías generales. Los resultados demuestran que mediante una correcta elección del valor de las variables se puede mejorar la seguridad y durabilidad del puente con un pequeño incremento del coste. Además, esta metodología es aplicable a cualquier tipo de estructura y material.[CA] Els ponts, com a part important d'una infraestructura, s'espera que reunisquen tots els requisits d'una societat moderna. Tradicionalment, l'objectiu principal en el disseny de ponts ha sigut aconseguir el menor cost mentres es garantix l'eficiència estructural. No obstant això, la preocupació per construir un futur més sostenible ha provocat un canvi en les prioritats de la societat. Estructures més ecològiques i durables són cada vegada més demandades. Davall estes premisses, els mètodes d'optimització heurística proporcionen una alternativa eficaç als dissenys estructurals basats en l'experiència. L'aparició de nous materials, dissenys estructurals i criteris sostenibles motiven la necessitat de crear una metodologia per al disseny automàtic i precís d'un pont real de formigó posttesat que considere tots estos aspectos. Per primera vegada, esta tesi estudia el disseny eficient de ponts de formigó posttesat amb secció en calaix des d'un punt de vista sostenible. Esta investigació integra criteris ambientals, de seguretat estructural i durabilitat en el disseny òptim del pont. La metodologia proposada proporciona múltiples solucions que a penes encarixen el cost i milloren la seguretat i durabilitat. Al mateix temps, es quantifica l'enfocament sostenible en termes econòmics, i s'avalua l'efecte que tenen els dits criteris en el valor òptim de les variables. En este context, es formula una optimització multiobjetivo que proporciona solucions eficients i de compromís entre els criteris econòmics, ecològics i socials. Un programa d'optimització del disseny selecciona la millor geometria, tipus de formigó, armadura i posttesat que complisquen amb els objectius seleccionats. S'ha triat com a cas d'estudi un pont continu en calaix de tres vans situat en la costa. Este mètode proporciona un major coneixement sobre esta tipologia de ponts des d'un punt de vista sostenible. S'ha estudiat el cicle de vida a través de l'avaluació del deteriorament estructural del pont a causa de l'atac per clorurs. S'examina l'impacte econòmic, ambiental i social que produïx el manteniment necessari per a estendre la vida útil del pont. Per tant, els objectius proposats per a un disseny eficient han sigut traslladats des de l'etapa inicial fins a la consideració del cicle de vida. Per a solucionar el problema de l'elevat temps de càlcul degut a l'optimització multiobjetivo i l'anàlisi per elements finits, s'han integrat xarxes neuronals en la metodologia proposada. Les xarxes neuronals són entrenades per a predir la resposta estructural a partir de les variables de disseny, sense la necessitat d'analitzar el pont. El problema d'optimització multiobjetivo es traduïx en un conjunt de solucions de compromís que representen objectius contraposats. La selecció final de les solucions preferides se simplifica per mitjà d'una tècnica de presa de decisions. Una tècnica estructurada convertix els juís basats en comparacions per parells d'elements amb un grau d'incertesa en valors numèrics que garantixen la consistència dels dits juís. Esta tesi proporciona una guia que estén i millora les recomanacions sobre el disseny d'estructures de formigó dins del context de desenrotllament sostenible. L'ús de la metodologia proposada porta a dissenys amb menor cost i emissions del cicle de vida, comparat amb dissenys que seguixen metodologies generals. Els resultats demostren que per mitjà d'una correcta elecció del valor de les variables es pot millorar la seguretat i durabilitat del pont amb un xicotet increment del cost. A més, esta metodologia és aplicable a qualsevol tipus d'estructura i material.García Segura, T. (2016). Efficient design of post-tensioned concrete box-girder road bridges based on sustainable multi-objective criteria [Tesis doctoral no publicada]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/73147TESI