Hybrid RSM-fuzzy modeling for hardness prediction of TiAlN coatings

In this paper, a new approach in predicting the hardness of Titanium Aluminum Nitrite (TiAlN) coatings using hybrid RSM-fuzzy model is implemented. TiAlN coatings are usually used in high-speed machining due to its excellent surface hardness and wear resistance. The TiAlN coatings were produced using Physical Vapor Deposition (PVD) magnetron sputtering process. A statistical design of experiment called Response Surface Methodology (RSM) was used in collecting optimized data. The fuzzy rules were constructed using actual experimental data. Meanwhile, the hardness values were generated using the RSM hardness model. Triangular shape of membership functions were used for inputs as well as output. The substrate sputtering power, bias voltage and temperature were selected as the input parameters and the coating hardness as an output of the process. The results of hybrid RSM-fuzzy model were compared against the experimental result and fuzzy single model based on the percentage error, mean square error (MSE), co-efficient determination (R2) and model accuracy. The result indicated that the hybrid RSM-fuzzy model obtained the better result compared to the fuzzy single model. The hybrid model with seven triangular membership functions gave an excellent result with respective average percentage error, MSE, R2 and model accuracy were 11.5%, 1.09, 0.989 and 88.49%. The good performance of the hybrid model showed that the RSM hardness model could be embedded in fuzzy rule-based model to assist in generating more fuzzy rules in order to obtain better prediction result

Application of ANFIS in Predicting of TiAlN Coatings Hardness

In this paper, a new approach in predicting the hardness of Titanium Aluminum Nitrite (TiAlN) coatings using Adaptive Neuro-Fuzzy Inference System (ANFIS) is implemented. TiAlN coated cutting tool is widely used in machining due to its excellent properties. The TiAlN coatings were formed using Physical Vapor Deposition (PVD) magnetron sputtering process. The substrate sputtering power, bias voltage and temperature were selected as the input parameters and the hardness as an output of the process. A statistical design of experiment called Response Surface Methodology (RSM) was used in collecting optimized data. The ANFIS model was trained using the limited experimental data. The triangular, trapezoidal, bell and Gaussian shapes of membership functions were used for inputs as well as output. The results of ANFIS model were validated with the testing data and compared with fuzzy and nonlinear RSM hardness models in terms of the root mean square error (RMSE) and model prediction accuracy. The result indicated that the ANFIS model using 3-3-3 triangular shapes membership function obtained better result compared to the fuzzy and nonlinear RSM hardness models. The result also indicated that the ANFIS model could predict the output response in high prediction accuracy even using limited training data

Application of ANFIS in Predicting of TiAlN Coatings Hardness

In this paper, a new approach in predicting the hardness of Titanium Aluminum Nitrite (TiAlN) coatings using Adaptive Neuro-Fuzzy Inference System (ANFIS) is implemented. TiAlN coated cutting tool is widely used in machining due to its excellent properties. The TiAlN coatings were formed using Physical Vapor Deposition (PVD) magnetron sputtering process. The substrate sputtering power, bias voltage and temperature were selected as the input parameters and the hardness as an output of the process. A statistical design of experiment called Response Surface Methodology (RSM) was used in collecting optimized data. The ANFIS model was trained using the limited experimental data. The triangular, trapezoidal, bell and Gaussian shapes of membership functions were used for inputs as well as output. The results of ANFIS model were validated with the testing data and compared with fuzzy and nonlinear RSM hardness models in terms of the root mean square error (RMSE) and model prediction accuracy. The result indicated that the ANFIS model using 3-3-3 triangular shapes membership function obtained better result compared to the fuzzy and nonlinear RSM hardness models. The result also indicated that the ANFIS model could predict the output response in high prediction accuracy even using limited training data

Application of ANFIS in predicting TiAlN coatings flank wear

In this paper, a new approach in predicting the flank wear of Titanium Aluminum Nitrite (TiAlN) coatings using Adaptive Network Based Fuzzy Inference System (ANFIS) is implemented. TiAlN coated cutting tool is widely used in machining due to its excellent resistance to wear. The TiAlN coatings were formed using Physical Vapor Deposition (PVD) magnetron sputtering process. The substrate sputtering power, bias voltage and temperature were selected as the input parameters and the flank wear as an output of the process. A statistical design of experiment called Response Surface Methodology (RSM) was used in collecting optimized data. The ANFIS model was trained using the limited experimental data. The triangular, trapezoidal, bell and Gaussian shapes of membership functions were used for inputs as well as output. The results of ANFIS model were validated with the testing data and compared with fuzzy rule-based and RSM flank wear models in terms of the root mean square error (RMSE), coefficient determination (R2) and model accuracy (A). The result indicated that the ANFIS model using three bell shapes membership function obtained better result compared to the fuzzy and RSM flank wear models. The result also indicated that the ANFIS model could predict the output response in high prediction accuracy even using limited training data

Intelligence Integration Of Particle Swarm Optimization And Physical Vapour Deposition For Tin Grain Size Coating Process Parameters

Optimization of thin film coating parameters is important in identifying the required output.Two main issues of the process of physical vapor deposition (PVD) are manufacturing costs and customization of cutting tool properties.The aim of this study is to identify optimal PVD coating process parameters.Three process parameters were selected,namely nitrogen gas pressure (N2),argon gas pressure (Ar),and Turntable Speed (TT),while thin film grain size of titanium nitrite (TiN) was selected as an output response.Coating grain size was characterized using Atomic Force Microscopy (AFM) equipment.In this paper,to obtain a proper output result,an approach in modeling surface grain size of Titanium Nitrite (TiN)coating using Response Surface Method (RSM) has been implemented. Additionally,analysis of variance (ANOVA) was used to determine the significant factors influencing resultant TiN coating grain size.Based on that,a quadratic polynomial model equation was developed to represent the process variables and coating grain size.Then,in order to optimize the coating process parameters,genetic algorithms (GAs) were combined with the RSM quadratic model and used for optimization work.Finally,the models were validated using actual testing data to measure model performances in terms of residual error and prediction interval (PI).The result indicated that for RSM,the actual coating grain size of validation runs data fell within the 95% (PI) and the residual errors were less than 10 nm with very low values, the prediction accuracy of the model is 96.09%.In terms of optimization and reduction the experimental data,GAs could get the best lowest value for grain size then RSM with reduction ratio of ≈6%, ≈5%, respectively

Modeling And Optimization Of Physical Vapour Deposition Coating Process Parameters For Tin Grain Size Using Combined Genetic Algorithms With Response Surface Methodology

Optimization of thin film coating parameters is important in identifying the required output.Two main issues of the process of physical vapor deposition (PVD) are manufacturing costs and customization of cutting tool properties.The aim of this study is to identify optimal PVD coating process parameters.Three process parameters were selected, namely nitrogen gas pressure (N2),argon gas pressure (Ar),and Turntable Speed (TT),while thin film grain size of titanium nitrite (TiN) was selected as an output response.Coating grain size was characterized using Atomic Force Microscopy (AFM) equipment.In this paper,to obtain a proper output result,an approach in modeling surface grain size of Titanium Nitrite (TiN)coating using Response Surface Method (RSM) has been implemented. Additionally,analysis of variance(ANOVA) was used to determine the significant factors influencing resultant TiN coating grain size.Based on that,a quadratic polynomial model equation was developed to represent the process variables and coating grain size.Then,in order to optimize the coating process parameters, genetic algorithms (GAs) were combined with the RSM quadratic model and used for optimization work.Finally,the models were validated using actual testing data to measure model performances in terms of residual error and prediction interval (PI).The result indicated that for RSM,the actual coating grain size of validation runs data fell within the 95% (PI) and the residual errors were less than 10 nm with very low values, the prediction accuracy of the model is 96.09%.In terms of optimization and reduction the experimental data,GAs could get the best lowest value for grain size then RSM with reduction ratio of ≈6%, ≈5%, respectively

Thin Film Roughness Optimization In The Tin Coatings Using Genetic Algorithms

Optimization is important to identify optimal parameters in many disciplines to achieve high quality products including optimization of thin film coating parameters. Manufacturing costs and customization of cutting tool properties are the two main issues in the process of Physical Vapour Deposition (PVD). The aim of this paper is to find the optimal parameters get better thin film roughness using PVD coating process. Three input parameters were selected to represent the solutions in the target data, namely Nitrogen gas pressure (N2), Argon gas pressure (Ar), and Turntable speed (TT), while the surface roughness was selected as an output response for the Titanium nitrite (TiN). Atomic Force Microscopy (AFM) equipment was used to characterize the coating roughness. In this study, an approach in modeling surface roughness of Titanium Nitrite (TiN) coating using Response Surface Method (RSM) has been implemented to obtain a proper output result. In order to represent the process variables and coating roughness, a quadratic polynomial model equation was developed. Genetic algorithms were used in the optimization work of the coating process to optimize the coating roughness parameters. Finally, to validate the developed model, actual data were conducted in different experimental run. In RSM validation phase, the actual surface roughness fell within 90% prediction interval (PI). The absolute range of residual errors (e) was very low less than 10 to indicate that the surface roughness could be accurately predicted by the model. In terms of optimization and reduction the experimental data, GAs could get the best lowest value for roughness compared to experimental data with reduction ratio of 46.75%

Particle swarm optimization algorithm to enhance the roughness of thin film in tin coatings

Nowadays, lots of disciplines require optimization to determine optimal parameters to accomplish top quality services which include parameters optimization of thin film coating. Modification of sharp tool characteristics and costs are two primary matters in the procedure of Physical Vapour Deposition (PVD). The purpose of this study is to figure out the optimal parameters in PVD coating process for better thin-film roughness. Three input parameters are chosen to describe the solutions over the target data, such as Nitrogen gas pressure (N2), Turntable speed (TT), and Argon gas pressure (Ar), although the surface roughness had been chosen being a result response of the Titanium nitrite (TiN). Atomic Force Microscopy (AFM) tools were applied to describe the roughness of coating layer. Within this research, a process of modelling using Response Surface Method (RSM) was applied for surface roughness of Titanium Nitrite (TiN) coating to get a best result. Particle Swarm Optimization (PSO) was applied as an optimization technique for the coating process to enhance characteristics of thin film roughness. In validation process, different experimental runs of actual data were conducted. It was found that residual error (e) is less than 10, to indicate that the model can accurately predict the surface roughness. Also, PSO could reduce the value of coating roughness at reduction of ≈ 48% to get a minimum value compared to actual data

Mono and Multi-Objective Optimization and Modeling of Machining Performance in Face Milling of Ti6Al4V Alloy

Titanium alloys are extensively used in numerous industries like aerospace, automotive, military, etc., due to their exclusive characteristics. But machining these alloys has always been challenging for manufacturers. This research investigates the effect of radial depth of cut on cutting forces, tool life, surface roughness (Ra), and material removal rate (MRR) during face milling of Ti6Al4V alloy. It also aims to perform mono and multi-objective optimization of response characteristics to determine the optimal input parameters, namely cutting speed, feed rate, and radial depth of cut. Taguchi method and analysis of variance (ANOVA) have been used for mono-objective optimization, whereas Taguchi-based Grey relational analysis (GRA) and Genetic algorithm (GA) have been used for multi-objective optimization. Regression analysis has been performed for developing mathematical models to predict Ra, tool life, average cutting forces, and MRR. According to ANOVA analysis, the most significant parameter for tool life is cutting speed. For MRR and average cutting force (Avg. FY), the most influential parameter is the radial depth of cut. On the other hand, feed rate is the most significant parameter for Ra and average feed force (Avg. FX). The optimal combination of input parameters for tool life and Avg. FY is 50 m/min cutting speed, 0.2 mm/rev feed rate, and 7.5 mm radial depth of cut. However, the optimal parameters for Ra are 65 m/min cutting speed, 0.2 mm/rev feed rate, and 7.5 mm radial depth of cut. For Avg. FX, the optimal conditions are 57.5 m/min cutting speed, 0.2 mm/rev feed rate, and 7.5 mm radial depth of cut. Similarly, for MRR, the optimal parameters are 65 m/min cutting speed, 0.3 mm/rev feed rate, and 12.5 mm radial depth of cut. A validation experiment has been conducted at the optimal Ra parameters, which shows an improvement of 31.29% compared to the Ra measured at the initial condition. A minor error has been found while comparing the experimental data with the predicted values calculated from the mathematical models. GRA for multi-objective (3 objectives: tool life, Ra, and Avg. FY) optimization has improved 55.81% tool life, 6.12% Ra, and 23.98% Avg. FY. ANOVA analysis based on grey relational grade has demonstrated that radial depth of cut is the most significant parameter for multi-objective (three objectives) optimization during the face milling of Ti6Al4V. The results obtained from the GRA considering four output characteristics (tool life, Ra, Avg. FY, and MRR) are compared with GA optimization results for both roughing and finishing, and a negligible deviation has been observed

A review on conventional and nonconventional machining of SiC particle-reinforced aluminium matrix composites

AbstractAmong the various types of metal matrix composites, SiC particle-reinforced aluminum matrix composites (SiCp/Al) are finding increasing applications in many industrial fields such as aerospace, automotive, and electronics. However, SiCp/Al composites are considered as difficult-to-cut materials due to the hard ceramic reinforcement, which causes severe machinability degradation by increasing cutting tool wear, cutting force, etc. To improve the machinability of SiCp/Al composites, many techniques including conventional and nonconventional machining processes have been employed. The purpose of this study is to evaluate the machining performance of SiCp/Al composites using conventional machining, i.e., turning, milling, drilling, and grinding, and using nonconventional machining, namely electrical discharge machining (EDM), powder mixed EDM, wire EDM, electrochemical machining, and newly developed high-efficiency machining technologies, e.g., blasting erosion arc machining. This research not only presents an overview of the machining aspects of SiCp/Al composites using various processing technologies but also establishes optimization parameters as reference of industry applications