Modelling and multiobjective optimization for productivity improvement in high speed milling of Ti–6Al–4V using RSM and GA

Productivity can be improved in machining by achieving higher material removal rate (MRR) and better surface finish at lower power consumption along with higher tool life. Present work focuses on analyzing power consumption, material removal rate; surface roughness and tool wear in high speed millin...

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Published in:	Journal of the Brazilian Society of Mechanical Sciences and Engineering Vol. 39; no. 12; pp. 5069 - 5085
Main Authors:	Sahu, Neelesh Kumar, Andhare, Atul B.
Format:	Journal Article
Language:	English
Published:	Berlin/Heidelberg Springer Berlin Heidelberg 01.12.2017 Springer Nature B.V
Subjects:	Correlation coefficients Cutting parameters Cutting speed Design of experiments Engineering Face milling Feed rate Genetic algorithms High speed machining Material removal rate (machining) Mechanical Engineering Milling (machining) Multiple objective analysis Optimization Power consumption Process parameters Production planning Productivity Response surface methodology Surface finish Surface roughness Technical Paper Titanium base alloys Tool life Tool wear Variance analysis Surface roughness Ti–6Al–4V Power consumption Response surface methodology MRR
ISSN:	1678-5878, 1806-3691
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Abstract	Productivity can be improved in machining by achieving higher material removal rate (MRR) and better surface finish at lower power consumption along with higher tool life. Present work focuses on analyzing power consumption, material removal rate; surface roughness and tool wear in high speed milling of Ti–6Al–4V using response surface methodology. Models are developed with experimental data measured after performing face milling operation sequentially using design of experiments. Developed models are validated and reformed using Analysis of variance (ANOVA) and stepwise backward elimination method. Developed models showed correlation coefficient ( R 2 ) more than 95% which means models can best explain the experimental data. Further, multiobjective optimization is performed to minimize power consumption; surface roughness and tool wear as well as to maximize MRR using response optimizer with desirability approach. Optimum process parameters obtained are: cutting speed = 133.5 m/min, feed rate = 0.14 mm/tooth and depth of cut = 2.33 mm. Validation of optimized results is done with three confirmation experiments at the optimum conditions and the responses are taken as average of the three confirmation experiments. Additionally, Pareto optimal points are found for conflicting objective functions using multiobjective genetic algorithm.
AbstractList	Productivity can be improved in machining by achieving higher material removal rate (MRR) and better surface finish at lower power consumption along with higher tool life. Present work focuses on analyzing power consumption, material removal rate; surface roughness and tool wear in high speed milling of Ti–6Al–4V using response surface methodology. Models are developed with experimental data measured after performing face milling operation sequentially using design of experiments. Developed models are validated and reformed using Analysis of variance (ANOVA) and stepwise backward elimination method. Developed models showed correlation coefficient (R2) more than 95% which means models can best explain the experimental data. Further, multiobjective optimization is performed to minimize power consumption; surface roughness and tool wear as well as to maximize MRR using response optimizer with desirability approach. Optimum process parameters obtained are: cutting speed = 133.5 m/min, feed rate = 0.14 mm/tooth and depth of cut = 2.33 mm. Validation of optimized results is done with three confirmation experiments at the optimum conditions and the responses are taken as average of the three confirmation experiments. Additionally, Pareto optimal points are found for conflicting objective functions using multiobjective genetic algorithm. Productivity can be improved in machining by achieving higher material removal rate (MRR) and better surface finish at lower power consumption along with higher tool life. Present work focuses on analyzing power consumption, material removal rate; surface roughness and tool wear in high speed milling of Ti–6Al–4V using response surface methodology. Models are developed with experimental data measured after performing face milling operation sequentially using design of experiments. Developed models are validated and reformed using Analysis of variance (ANOVA) and stepwise backward elimination method. Developed models showed correlation coefficient ( R 2 ) more than 95% which means models can best explain the experimental data. Further, multiobjective optimization is performed to minimize power consumption; surface roughness and tool wear as well as to maximize MRR using response optimizer with desirability approach. Optimum process parameters obtained are: cutting speed = 133.5 m/min, feed rate = 0.14 mm/tooth and depth of cut = 2.33 mm. Validation of optimized results is done with three confirmation experiments at the optimum conditions and the responses are taken as average of the three confirmation experiments. Additionally, Pareto optimal points are found for conflicting objective functions using multiobjective genetic algorithm.
Author	Andhare, Atul B. Sahu, Neelesh Kumar
Author_xml	– sequence: 1 givenname: Neelesh Kumar orcidid: 0000-0001-6488-7585 surname: Sahu fullname: Sahu, Neelesh Kumar email: neeleshmecher@gmail.com organization: Department of Mechanical Engineering, VNIT – sequence: 2 givenname: Atul B. surname: Andhare fullname: Andhare, Atul B. organization: Department of Mechanical Engineering, VNIT
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Snippet	Productivity can be improved in machining by achieving higher material removal rate (MRR) and better surface finish at lower power consumption along with...
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SubjectTerms	Correlation coefficients Cutting parameters Cutting speed Design of experiments Engineering Face milling Feed rate Genetic algorithms High speed machining Material removal rate (machining) Mechanical Engineering Milling (machining) Multiple objective analysis Optimization Power consumption Process parameters Production planning Productivity Response surface methodology Surface finish Surface roughness Technical Paper Titanium base alloys Tool life Tool wear Variance analysis
Title	Modelling and multiobjective optimization for productivity improvement in high speed milling of Ti–6Al–4V using RSM and GA
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