Modelling and Optimization of Surface Roughness and Specific Tool Wear in Milling Process

The present study has been carried out to optimize three machining parameters in the milling process to achieve minimum surface roughness and tool wear along with the maximum material removal rate. A specific tool wear factor has been defined to evaluate both tool wear and material removal rate parameters simultaneously and the surface roughness was considered as the second output parameter. A set of experiments was designed using a DOE technique and conducted on a milling machine. The experimental data then was applied to develop different mathematical models and the best model was chosen based on analysis of variance (ANOVA). Three proposed methods of optimization with different natures were used to determine optimal output parameters based on selected models. The comparison between these methods showed that Regression-response optimization was superior to Simulated Annealing (SA) algorithm and Goal-attainment method. The Simulated Annealing (SA) algorithm also represented less error function compared to goal-attainment methods. The results of optimization revealed that optimum values for cutting speed and feed rate were ranged from 312 to 314 m/min and 0.085 to 0.12 mm/rev⸱tooth, respectively, while all optimization methods reached the same value of 1.0 mm for depth of cut parameter

Machine Learning-Based Modelling and Meta-Heuristic-Based Optimization of Specific Tool Wear and Surface Roughness in the Milling Process

The purpose of this research is to investigate different milling parameters for optimization to achieve the maximum rate of material removal with the minimum tool wear and surface roughness. In this study, a tool wear factor is specified to investigate tool wear parameters and the amount of material removed during machining, simultaneously. The second output parameter is surface roughness. The DOE technique is used to design the experiments and applied to the milling machine. The practical data is used to develop different mathematical models. In addition, a single-objective genetic algorithm (GA) is applied to numerate the optimal hyperparameters of the proposed adaptive network-based fuzzy inference system (ANFIS) to achieve the best possible efficiency. Afterwards, the multi-objective GA is employed to extract the optimum cutting parameters to reach the specified tool wear and the least surface roughness. The proposed method is developed under MATLAB using the practically extracted dataset and neural network. The optimization results revealed that optimum values for feed rate, cutting speed, and depth of cut vary from 252.6 to 256.9 (m/min), 0.1005 to 0.1431 (mm/rev tooth), and from 1.2735 to 1.3108 (mm), respectively