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Applied Soft Computing 13 (2013) 15431551

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Applied Soft Computing


journal homepage: www.elsevier.com/locate/asoc

Modeling and prediction of machining quality in CNC turning process


using intelligent hybrid decision making tools
C. Ahilan a,1 , Somasundaram Kumanan b,1 , N. Sivakumaran c,1 , J. Edwin Raja Dhas d,
a
Department of Mechanical Engineering, Oxford Engineering College, Tiruchirappalli, 620009 Tamil Nadu, India
b
Department of Production Engineering, National Institute of Technology Tiruchirappalli, 620015 Tamil Nadu, India
c
Department of Instrumentation and Control Engineering, National Institute of Technology Tiruchirappalli, 620015 Tamil Nadu, India
d
Department of Automobile Engineering, Noorul Islam Centre for Higher Education, Nagercoil 629180, Tamil Nadu, India

a r t i c l e i n f o a b s t r a c t

Article history: Decision-making process in manufacturing environment is increasingly difcult due to the rapid changes
Received 5 December 2011 in design and demand of quality products. To make decision making process (selection of machin-
Received in revised form 19 January 2012 ing parameters) online, effective and efcient articial intelligent tools like neural networks are being
Accepted 13 March 2012
attempted. This paper proposes the development of neural network models for prediction of machining
Available online 5 May 2012
parameters in CNC turning process. Experiments are designed based on Taguchis Design of Experiments
(DoE) and conducted with cutting speed, feed rate, depth of cut and nose radius as the process parameters
Keywords:
and surface roughness and power consumption as objectives. Results from experiments are used to train
CNC turning
Taguchi method
the developed neuro based hybrid models. Among the developed models, performance of neural network
Neural network model trained with particle swarm optimization model is superior in terms of computational speed and
Genetic algorithm accuracy. Developed models are validated and reported. Signal-to-noise (S/N) ratios of responses are cal-
Particle swarm optimization culated to identify the inuences of process parameters using analysis of variance (ANOVA) analysis. The
Response Surface Methodology developed model can be used in automotive industries for deciding the machining parameters to attain
Power consumption quality with minimum power consumption and hence maximum productivity.
Surface roughness 2012 Elsevier B.V. All rights reserved.

1. Introduction cutting parameters are determined based on experience or by use


of a handbook which does not guarantee optimal performance [5].
Turning is one of the important and widely used machining It is necessary to select the most appropriate machining settings
processes in engineering industries. In turning, the cutting con- in order to improve cutting efciency, process at low cost and
ditions such as cutting speed, feed rate, depth of cut, features of produce high-quality products [68]. So it needs well suited pre-
tools and work piece materials affects the process efciency and dictive model for process studies. Researchers attempt different
performance characteristics [1,2]. Performance evaluation of CNC modeling techniques to investigate the parameters of machining
turning is based on the performance characteristics like surface process.
roughness, material removal rate, tool wear, tool life, cutting force Quality control techniques such as factorial experiment [9],
and power consumption. Very few research attempts have been design of experiment [10] and Taguchi method [11] have been
done to estimate the signicance of energy required for the machin- employed to predict surface roughness. Taguchi method adopts
ing process. Recent increase in energy demand and constraints in a set of orthogonal arrays to investigate the effect of parameters
supply of energy becomes a priority for the manufacturing indus- on specic quality characteristics to decide the optimum parame-
try. Surface quality is an important performance to evaluate the ter combination [12,13]. These kinds of arrays use a small number
productivity of machine tools as well as machined components of experimental runs to analyze the quality effects of parame-
[3]. Surface roughness is the critical quality indicator for machined ters as well as the optimum combination of parameters. Hence,
surfaces [4]. In todays manufacturing industry, special attention is the Taguchi method has become a powerful design of experiment
given to surface nish and power consumption. Usually, the desired method.
Response Surface Method (RSM) is a collection of mathemati-
cal and statistical method useful for the modeling and analysis of
engineering problems in which a response of interest is inuenced
Corresponding author. Tel.: +91 04651 250566/366297;
by several variables and the objective is to optimize the response.
fax: +91 04651 257266/250266.
E-mail address: edwinrajadhas@rediffmail.com (J. Edwin Raja Dhas). The rst step in RSM is to nd a suitable approximation for the true
1
Tel.: +91 0431 2503033/2503507; fax: +91 0431 2500133/2503502. functional relationship between response of interest Y and a set of

1568-4946/$ see front matter 2012 Elsevier B.V. All rights reserved.
http://dx.doi.org/10.1016/j.asoc.2012.03.071
1544 C. Ahilan et al. / Applied Soft Computing 13 (2013) 15431551

controllable variables {X1 , X2 , . . ., Xn }. Usually when the response machining quality for a given set of process parameters. Finally
function is not known or non-linear, a general model is in the form: response surface models are generated to validate the adequacy of
the developed models. The developed technique promotes man-

n

n

n

Y = b0 + bi Xi + bij Xij + (1) ufacturers to develop unmanned factories to achieve the highest
level for automation.
i=1 i=1 j=1

where the expected response is Y and bs are the regression coef-


2. Neural network models
cients to be estimated. The least square technique is being used
to t a model equation containing the input variables by minimiz-
The use of neural network models is vital in the modern manu-
ing the residual error measured by the sum of square deviations
facturing environment. Neural networks are dynamic systems that
between the actual and estimated responses. The calculated coef-
consist of processing units called neurons with weighted connec-
cients or the model equations, however, need to be tested for
tions to each other. Neural networks can learn, remember and
statistical signicance. RSM [14] is applied to nd a set of process
retrieve data. The signicant functions of neural network are tack-
variables that produce the desired surface nish. RSM was devel-
ling non-linearity and mapping inputoutput information. The
oped to predict surface roughness end milling titanium alloy using
different types of neural networks which are in practice are back
uncoated tungsten carbide inserts [15].
propagation neural network, counter propagation neural network
ANOVA test is performed using F-ratio. F ratio [16] measures the
and radial basis function neural network. Each intelligent technique
signicance of the model under investigation with respect to the
has certain strengths and weaknesses and they cannot be applied
variance of all the terms included in the error term at the desired
universally to every problem. This limitation is the central driv-
signicance level, .
ing force behind the creation of intelligent hybrid systems where
Checks are made to determine whether the model actually
two or more techniques are combined in a manner that overcomes
describes the experimental data by determining R2 coefcient. The
the limitations of individual techniques. The motivation for com-
adequacy of the model is investigated by the examination of residu-
bining different intelligent techniques is multiplicity of application
als. The residuals, which are the difference between the respective,
tasks, technique enhancement and realizing multifunctional tasks
observe responses and the predicted responses are examined using
[24]. Hence optimization techniques like GA and PSO algorithms
the normal probability plots of the residuals and the plots of the
are employed in development of neural network models.
residuals versus the predicted response. If the model is adequate,
the points on the normal probability plots of the residuals should
form a straight line. On the other hand the plots of the residuals 2.1. Back propagation neural network model
versus the predicted response should be structure less, that is, they
should contain no obvious patterns. Back propagation neural network (BPNN) is a multiple layer
Due to the inadequacy and inefciency of the linear regres- ANN with input layer, output layer and some hidden layers between
sion models to explain the nonlinear properties existing between the input and output layers. Its learning procedure is based on gra-
machining parameters, intelligent systems such as Articial Neural dient search with least mean squared optimality criteria. Once the
Network (ANN), fuzzy logic and expert system have been emerged. input data is fed to the nodes in the input layer (oi ), this will be fed
ANN is a good technique used to handle problems of nonlin- to nodes (j) in the hidden layer through weighting factors (wji ).
earity. ANNs trained with back propagation algorithm [17,18] have The net input to node j:
been used to predict the weld bead geometry and penetration in 
shielded metal-arc welding process. In real-world applications, the netj = wji oi bj (2)
back-propagation algorithm employed in ANN cannot guarantee i
an optimal solution since it may converge to a set of sub-optimal
weights from which it cannot escape. Fuzzy control [19] systems where bj is the bias over node j.
are effective to the uncertain, nonlinear as well as dynamic time- The output of the node j:
varying processes control systems such as machining process. A
model is developed using fuzzy logic for the selection of cutters and 1
oj = (3)
machining conditions [20]. Optimization techniques like genetic 1 + enetj
algorithm, particle swarm optimization and articial bee colony
Similarly the outputs from nodes in the hidden layer are fed into
algorithm are applied to optimize various manufacturing processes.
nodes in the output layer. This process is called the feed forward
Prediction of surface roughness with genetic algorithm is pro-
stage. After feed forward, calculation output (opk ) can be obtained
posed [21,22]. The main disadvantage of GA is that it requires a
from nodes in the output layer. In general, the output opk will not
higher computational power. PSO is used for nding the optimal
be the same as the desired known target tpk . Therefore the average
parameters for submerged arc weld operations [23]. PSO follows a
system error is:
collaborative population based search, which is based on the social
behavior of bird ocking and sh schooling. PSO is good in arriv- 1 
ing at best solution by having memory of the previous experience. E= (tpk opk )2
2p
Articial bee colony algorithm is employed to optimize multi pass p k
milling operation.
Each intelligent technique has particular strength and weakness The error is then back propagated from nodes in the output layer to
and this made it necessary for combining two or more intelli- nodes in the hidden layer using gradient search method p wkj =
gent tools to improve the performance. The goal is to combine (E/wkj ) = k oj delta value for output layer is:
a technique that has weakness in a particular function with a
technique that has strength in the same function [24]. Hybrid k = ok (1 ok )(tk ok )
algorithms are successfully applied for various manufacturing pro-
delta value for hidden value is:
cesses [2527]. This paper addresses the development of hybrid
algorithms employing neural network embedded with genetic

j = oj (1 oj ) wkj k
algorithm and particle swarm optimization technique to predict
C. Ahilan et al. / Applied Soft Computing 13 (2013) 15431551 1545

This process is called back propagation stage. After all examples are
trained the system will collect adjusted weights according to:

wji = wji
p

Updating of weights is done according to

wji (n + 1) = wji (n) + wji (4)

2.2. Neural network model trained with genetic algorithm

Genetic algorithm is widely used to solve optimization prob-


lems. The standard genetic algorithm proceeds as follows: an initial
population of individuals (that is, a set of solutions for the given
problem represented by chromosomes) is generated at random or
heuristically. The data is normalized in the range 0.10.9 by using
Eq. (4)
 x x  Fig. 1. Schematic diagram of CNC set-up for turning operation.
i min
xnorm = 0.1 + 0.8 (5)
xmax xmin
The steps used in genetic algorithm are (a) initializing the pop- time to favor local search over global search. When the number of
ulation randomly, (b) cross over with probability and (c) mutation iterations is equal to the total number of particles, goal is compared
with probability. In each generation, the individuals in the current with the error produced by the GBest weights. If the error produced
population are decoded and evaluated according to some prede- by the GBest weights are less than or equal to the goal, weights in
ned quality criterion, referred as the tness function. To form a the GBest are used for testing and prediction. Otherwise weights of
new population for next generation, the individuals are selected minimum error are stored in GBest and the iterations are repeated
according to their tness. The selected best population will undergo until goal reached.
crossover and mutation operation to produce new offsprings. Then
some or all population are replaced with newly created offspring 3. Data acquisition
based on their tness. This action is motivated by a hope that the
new population will be better than the old one. This is repeated until CNC (FANUC control) lathe with 7.5 kW spindle power and max-
some condition (for example number of populations or improve- imum spindle speed of 4500 rpm is used to perform the machining
ment of the best solution) is satised. If GA has been designed well, operation. Schematic diagram of the experimental set-up used is
the population will converge to an optimal solution to the problem. shown in Fig. 1. FLUKE 43B power quality analyzer to measure
the power consumption (W) of cutting process is connected to
2.3. Neural network model trained with particle swarm the power supply of CNC turning center as shown in Fig. 2. Power
optimization consumption is measured for each setting of machining operation
and idle running operation. Taylor-Hobson Talysurf as is used to
In this proposed model, back propagation algorithm of neural measure surface roughness. AISI 304 stainless steel of 70 HRC in
network is replaced by PSO algorithm. Here the randomly gener- the form of round bars with 50 mm diameter and 200 mm cut-
ated weights are assigned in each link of neural network. In particle ting length are used for machining. Photograph of the experimental
swarm optimization algorithm, PBest is the location of the best setup is shown in Fig. 3. The percentage of chemical composition of
solution of a particle has achieved so far. GBest is the location of work material is 0.08 C, 1820 Cr, 2 Mn, 810.5 Ni, 0.045 P, 0.03 S, 1
the best solution that any neighbor of a particle has achieved so
far. Initially random numbers are generated for each particle and
these random values are considered as PBest and present weights.
Velocity is calculated using Eq. (6) and added with the present
weight in each link of neural network. For each particle, the newly
calculated weights are compared with the PBest weights and the
minimum error produced weights are stored in PBest. Initial veloc-
ity V is assumed to be 1 and GBest is the weights of minimum error
produced particle. New weight is calculated as in Eq. (7).

Velocity[] = wVelocity[] + C1 rand1 (PBest[] present[])

+ C2 xrand2 (GBest[] present[]) (6)

Present[] = Present[] + Velocity[] (7)

where C1 and C2 are two positive constants named learning factors.


rand1 and rand2 are two random functions in the range [0, 1]. w is
an inertia weight to control the impact of the previous history of
velocities on the current velocity. The operator w plays the role of
balancing the global search and the local search; and was proposed
to decrease linearly with time from a value of 1.40.5. As such,
global search starts with a large weight and then decreases with Fig. 2. Photograph of the Fluke 43b power quality analyzer.
1546 C. Ahilan et al. / Applied Soft Computing 13 (2013) 15431551

Hidden
layers
Input Output
layer layer

Cutting Speed

Feed rate Surface


roughness

Depth of cut Power


Consumption
Nose radius

Fig. 4. Developed structure of BPNN model.


Fig. 3. Photograph of CNC experimental set-up.

4. Development of proposed neural network models


Si and remaining Fe. It is mainly used for chemical equipments, food
processing equipment, dairy equipment, textile dyeing equipment,
To handle multiplicity of application tasks and realizing multi-
cryogenic vessels and hospital surgical equipment. Standard car-
functionality different neural network models are proposed and
bide tool inserts CNMG120404, CNMG120408 and CNMG120412
developed.
are used for machining.
To perform the experimental design, three levels of machining
parameters cutting speed in m/min, A (100.125.150) feed rate in 4.1. Development of proposed NNBPN model
mm/rev, B (0.05, 0.1, 0.15), depth of cut in mm, C (0.20, 0.35, 0.50)
and nose radius in mm, D (0.4, 0.8, 1.2). An appropriate orthogo- Topography of the proposed NNBPN model to predict sur-
nal array for the experiments must have the degrees of freedom face roughness and power consumption is shown in Fig. 4.
greater than or at least equal to those for the process parame- It is feed forward back propagation network trained with
ters. In this study, an L27 (34 ) orthogonal array is used because it LevenbergMarquardt back propagation algorithm. Experimental
has 26 degrees of freedom more than the 8 degrees of freedom data is used for training and testing the developed back propagation
in the machining parameters. Experimental combinations of the neural network model. The learning function is gradient descent
machining parameters and the observations of power consump- algorithm with momentum weight and bias learning function. The
tion and surface roughness are shown in Table 1. Responses from number of hidden layers and neurons are determined through a
experimentation are used to develop the proposed neural network trial and error method, in order to accommodate the converged
models. error. The structure of the developed neural network is 4962 (4
neurons in the input layer, 9 neurons in 1st hidden layer and 6 neu-
rons in 2nd hidden layer and 2 neurons in the output layer). With
Table 1
Experimental design and their responses. a learning rate of 0.57 and a momentum term of 0.9, the network
is trained for 10,000 iterations. Error between the desired and the
Trial A B C D Power (W) Surface
actual outputs is less than 0.001 at the end of training process.
numbers roughness
(m)

1 1 1 1 1 213 2.04
4.2. Development of proposed NNGA model
2 1 1 2 2 320 1.74
3 1 1 3 3 332 2.02 The proposed method to predict machining using NNGA model
4 1 2 1 2 283 1.25 is depicted in Fig. 5. The topology of a neural network model as
5 1 2 2 3 340 1.1
shown in Fig. 4 is dened and will remain xed after the initial-
6 1 2 3 1 393 1.02
7 1 3 1 3 275 1.5 ization. The learning function is gradient descent algorithm with
8 1 3 2 1 350 1.12 momentum weight and bias learning function. The transfer func-
9 1 3 3 2 620 1.35 tion and error criteria (mean square error) are xed. Training is
10 2 1 1 2 392 1.82 done by genetic algorithm search. In this application each string or
11 2 1 2 3 438 1.52
12 2 1 3 1 441 1.78
chromosome in the population represents the weight and bias val-
13 2 2 1 3 391 1.04 ues of the network. The initial population is generated randomly.
14 2 2 2 1 570 0.84 By selecting suitable parameters like selection criteria, probabil-
15 2 2 3 2 668 1.02 ity of crossover, probability of mutation, initial population etc., to
16 2 3 1 1 394 1.16
the GA, high efciency and performance is achieved. The objective
17 2 3 2 2 617 1.26
18 2 3 3 3 760 1.48 function is minimization of the mean square error. Fitness function
19 3 1 1 3 448 2.02 considered is the minimum of the mean square error and computed
20 3 1 2 1 516 1.54 by recalling the network. After getting the tness values of all chro-
21 3 1 3 2 585 1.94 mosomes, they are ranked based on the best tness values. For the
22 3 2 1 1 476 1.08
23 3 2 2 2 625 1.16
production of offspring for next generation half of the best-ranked
24 3 2 3 3 765 1.42 population is selected. This half population undergo crossover with
25 3 3 1 2 528 1.46 crossover probability (0.9). This again will be mutated to give a new
26 3 3 2 3 706 1.38 offspring, with mutation probability (0.08), which is combined with
27 3 3 3 1 873 1.64
selected best population to form a new population for the next
C. Ahilan et al. / Applied Soft Computing 13 (2013) 15431551 1547

Network with Start


Results Network optimal weight set Network Results
Testing Prediction
Find out random values and stored as pBest and present
weights, Assign Iteration = 0 and i = 0

Evaluation of
Network Weight For each particle, calculate the output of neural network and error
objective
Matrix function

Find out the minimum error produced particle


Store the corresponding weights in gBest
Generation of Ranking
optimized Data from
weights Experiments Find velocity of ith particle and add velocity to the present weights to get
new weights

Yes
Cross over
Store the newly
Error(new weights) generated weights in
< Error(pBest) pBest
Mutation
No

Velocity (next particle) = Velocity(current particle)

Fig. 5. NNGA model for prediction of machining quality. Iteration = Iteration + 1, i = i+1

Yes
No
Is Iteration gBest = weights(minimum error
= No. of produced particle)
Particles
Yes
Parent 1 0.5 No
Is goal weights in gBest are
1 Iteration = 0, i = 0 reached? used for testing and
prediction
1.0
X1
1.7
2.0 -0.4 -0.4 -1.4
1 Stop
2.0
0.7
0.9 -0.3
X2 1.4 1.0 1.2 1.5
2 2 1.0 Y1 Fig. 7. Flowchart for training the neural network using PSO algorithm.
-0.9 -0.6 1
0.7 1.8
X3
1.0 2.0 Y2 generation. Typical neural network model of 452 architecture
-0.4 2.0 2 1.4
3 --0.7 with weights is depicted in Fig. 6.
2.0 2
1.0
0.6
1.3 0.9 1.0 Where X1 , X2 , . . . are inputs and Y1 , Y2 , . . . are outputs. This
X4 2.0 2.0 0.6
3
1.0 will be continued till the stopping criteria are reached. The stop-
4 1.5 1.6 2.0
2.0 -1.9 1.0 ping criteria for this network are the number of generations. Neural
2.0
-1.0 1.6 -0.8 network coded with optimal weight set chromosome produced by
0.4 genetic algorithm is forwarded to predict the quality of weld.
1.7

2 4.3. Development of proposed NNPSO model

Parent 2 1.9
In the development of NNPSO model, back propagation algo-
rithm of neural network is replaced by PSO algorithm. The data
1 required for training and testing the NNPSO model is taken from
-0.7
X1 Table 1. PSO algorithm used to train the neural network is shown
1.7
2.0 -0.2 -1.4 -1.7 in Fig. 7. The total number of population size is 40. The dimension
1
0.7
2.0 size is 4 and the value of inertia weight is 0.51.4. Number of itera-
0.9 -0.8
X2 1.4 1.0 1.2 0.5 tions allowed is equal to total number of particles. Value of velocity
2 1.0 Y1
2 factors (C1 and C2 ) is taken as 1.4.
-0.3 -0.6 1
1.7 1.8
X3
1.0 2.0 5. Validation of the developed models
-0.4 1.0 2 1.4 Y2
3 --0.7 2.0 2
0.6 1.0
0.3 1.0
X4 1.6 The developed models are validated from conrmatory tests.
2.0 1.0 2.0 0.9
4 1.5 3 Table 2 shows the outcomes from conrmatory tests. Table 3 shows
1.6 2.0
2.0 -1.4 1.3
2.0
the accuracy of the values predicted from the developed mod-
-1.0 -0.6 -0.4 els. The percentage of error predicted by the developed models
1.4 are calculated by [{Observed value predicted value}/predicted
1.7
value] 100.
2 Time required for training the developed network models are
compared in terms of number of epochs as shown in Figs. 8 and 9.
Fig. 6. Typical neural network model coded with weights. The congurations of the computing machine used are Intel Pen-
tium IV 1.8 GHz processor, 512 MB RAM and 80 GB Hard Disk Drive.
1548 C. Ahilan et al. / Applied Soft Computing 13 (2013) 15431551

Table 2
Results from conrmatory experiment.

Test no. Cutting speed Feed rate Depth of cut Nose radius Observed values
(m/s) (mm/rev) (mm) (mm)

Power Surface
consumption roughness
(W) (m)

1 100 0.1 0.2 0.4 245 1.14


2 125 0.15 0.5 0.8 815 1.35
3 150 0.05 0.35 1.2 526 1.92

Table 3
Results from the developed models in terms of percentage error.

Percentage of error BPNN model for Percentage of error NNGA model for Percentage of error NNPSO model for

Power consumption Surface Power Surface Power Surface


roughness consumption roughness consumption roughness

2.94 3.63 1.606 3.06 1.6 2.63


1.74 9.39 1.49 4.92 0.617 2.87
1.68 4.43 0.94 2.673 0.766 2.12

5.1. Analysis of CNC turning parameters on power consumption dominant parameter for power consumption followed by depth of
and surface roughness cut (C) and feed rate (B). Nose radius (D) has a little effect on power
consumption. Contribution of parameters on power consumption
Power consumption and surface roughness have lower-the- is identied using ANOVA and presented in Table 4. Because of the
better criterion. The S/N ratios of responses are computed using lower-the-better characteristics, highest S/N ratio in each factor
(8) and (9). The main effects plot for power consumption is was desirable to obtain minimum power consumption. The S/N
shown in Fig. 10. Higher the difference between the minimum ratio ij for the ith performance characteristic in the jth experiment
and maximum S/N ratios in each factor is, higher the effect on the is expressed in Eq. (8).
power consumption. It clearly shows that cutting speed (A) was a
ij = 10 log(Lij ) (8)

For lower-the-better performance characteristic, Lij is expressed


450
in Eq. (9).
400
1 2
n
350
Lij = yijk (9)
300 n
Epochs

k=1
250
200 where k is number of tests, yijk is experimental value of the ith
150 performance characteristic in the jth experiment at the kth tests.
100
S/N ratio of four factors main effects plot for surface roughness
is shown in Fig. 11. The contribution of the parameters on surface
50
roughness is identied using ANOVA and presented in Table 5.
0
1 2 3 4 5 6 7 8
Trial Nos (Surface roughness)
Main Effects Plot for S/N ratio-Power Consumption
BPNN NNGA NNPSO
Data Means
Fig. 8. Training time required by the developed models for surface roughness pre-
A B
diction. -50

450 -52
400
350 -54

300
Epochs

-56
Mean

250 100 125 150 0.05 0.10 0.15


200
C D
150 -50
100
50 -52

0
-54
1 2 3 4 5 6 7 8
Trial Nos (Power consumption)
-56
BPNN NNGA NNPSO 0.20 0.35 0.50 0.4 0.8 1.2

Fig. 9. Training time required by the developed models for power consumption
prediction. Fig. 10. Parameters (A, B, C and D) main effect plot for power consumption.
C. Ahilan et al. / Applied Soft Computing 13 (2013) 15431551 1549

Table 4
Analysis of variance analysis for power consumption.

Factor DOF SS MS F value % contribution

A 2 123.18 61.59 86.75 50.23


B 2 32.11 16.05 22.61 13.09
C 2 72.73 36.36 51.21 29.66
D 2 4.5 2.25 3.17 1.84
Error 18 12.69 0.71 5.18

Total 26 245.21 100.00

Table 5
Analysis of variance analysis for surface roughness.

Factor DOF SS MS F value % contribution

A 2 7.55 3.77 7.69 6.41


B 2 87.74 43.87 89.53 74.45
C 2 9.14 4.57 9.33 7.76
D 2 4.67 2.33 4.76 3.96
Error 18 8.75 0.49 7.42

Total 26 117.85 100.00

Table 6
R2 value of response surface models for power consumption and surface roughness.

Response surface regression model R2 value for power consumption R2 value for surface roughness

Linear 89.09% 32.60%


Linear + square 91.31% 92.51%
Linear + interaction 96.41% 36.84%
Full quadratic (linear + square + interaction) 98.63% 96.75%

5.2. Development of response surface models Quadratic equation:

Response surface model have linear model, quadratic model, Y = b0 + b1 X1 + b2 X2 + b3 X3 + b4 X4 + b5 (X1 )2 + b6 (X2 )2
interaction model and full quadratic model and are as follows (for + b7 (X3 )2 + b8 (X4 )2 (11)
four input parameters):
Linear equation:
Interaction equation:

Y = b0 + b1 X1 + b2 X2 + b3 X3 + b4 X4 (10) Y = b0 + b1 X1 + b2 X2 + b3 X3 + b4 X4 + b5 X1 X2 + b6 X1 X3

+ b7 X1 X4 + b8 X2 X3 + b9 X2 X4 + b10 X3 X4 (12)

Second order equation (Full model)

Y = b0 + b1 X1 + b2 X2 + b3 X3 + b4 X4 + b5 (X1 )2 + b6 (X2 )2
Main Effects Plot for S/N ratio-Surface Roughness
Data Means + b7 (X3 )2 + b8 (X4 )2 + b9 X1 X2 + b10 X1 X3 + b11 X1 X4 + b12 X2 X3

A B + b13 X2 X4 + b14 X3 X4 (13)


-1 R2 values for power consumption model is tabulated in Table 6 and
-2 the desired full quadratic model is in Eq. (14).
-3 Power consumption = 1192.36 + 19.1028 X1 1913.93 X2
-4
513.16 X3 + 450.454 X4 0.0617 X12 4755.56 X22
-5
Mean

313.58 X32 206.597 X42 + 10.5422 X1 X2


100 125 150 0.05 0.10 0.15
C D + 4.2193 X1 X3 1.1089 X1 X4 + 8714.07 X2 X3
-1
+ 118.889 X2 X4 + 110.37 X3 X4 (14)
-2
where X1 is cutting speed, X2 is feed rate, X3 is depth of cut and X4
-3
is nose radius.
-4 The normal probability plot of the residual for power consump-
-5
tion is shown in Fig. 12. R2 values for surface roughness model is
tabulated in Table 6 and full quadratic model is given in Eq. (15).
0.20 0.35 0.50 0.4 0.8 1.2
Surface roughness = 9.80674 0.07608 X1 52.8926 X2

Fig. 11. Parameters (A, B, C and D) main effect plot for surface roughness. 9.17185 X3 + 0.33241 X4 + 0.00026 X12 + 198.00 X22
1550 C. Ahilan et al. / Applied Soft Computing 13 (2013) 15431551

Table 7
Validation test results of developed RS models for power consumption and surface roughness.

RS model value Error in %

Power consumption (W) Surface roughness (m) Power consumption (W) Surface roughness (m)

227 1.18 7.35 3.51


793 1.4 2.70 3.70
509 1.77 3.23 7.81

+ 9.18519 X32 0.10417 X42 + 0.05404 X1 X2 6. Results

+ 0.01849 X1 X3 0.00002 X1 X4 + 5.45185 X2 X3 Experiments are conducted in CNC machine using Taguchis
0.13333 X2 X4 + 0.0037 X3 X4 (15) principles. Results from experimentation are used to train and test
the developed neural network models. The performance of the
developed hybrid neural network models is measured in terms of
computational accuracy and speed. Conrmatory tests are done to
The normal probability plot of the residuals for surface rough- validate this approach. From Table 6 the predictive error computed
ness is shown in Fig. 13. The developed model for power using NNPSO is less compared with other developed models. The
consumption and surface roughness is validated by conducting reason is that NNPSO model searches solution in the search space
experiments (new set of input conditions) and their results are different from other neural network models. It maintains a inter-
presented in Table 7. nal memory to store the Gbest and Pbest solutions. Each individual
in the population tries to emulate the Gbest and Pbest solutions in
the memory by updating two PSO equations. But NNGA model iter-
atively searches for several good individuals in the population, and
make the population to emulate the best solutions found in that
Normal Probability Plot generation through reproduction, crossover and mutation opera-
(response is Power consumption) tors. Hence it requires substantial computational time to perform
99
decision making whereas back propagation algorithm training net-
95 work may converge to a set of sub-optimal weights. Hence the
90 effectiveness of NNPSO model in nding the true global optimal
80 solution is competent than the other neural network models. The
70 developed neural network model with PSO predicts the output with
Percent

60
50 an accuracy of error is hardly less than 2%.
40 Results in Figs. 8 and 9 indicate that the developed ANN model
30
20 trained with PSO needs minimum number of epochs and hence
10
computational time required is less. Experimental data from Table 1
5 are used for analyzing the inuence of process parameters on
responses (power consumption and surface roughness) and build-
1 ing the response surface (RS) model of CNC turning process. Effect of
-50 -25 0 25 50 75
Residual
CNC turning parameters on power consumption and surface rough-
ness are evaluated using ANOVA and calculation of S/N ratio. For
power consumption (Fig. 10 and Table 4) cutting speed is the most
Fig. 12. Developed response surface models normal probability plot for power
critical factor followed by depth of cut, feed rate and nose radius
consumption.
whereas feed rate (Fig. 11 and Table 5) has a signicant effect

Normal Probability Plot


(response is Surface roughness)
99

95

90

80
Percent

70
60
50
40
30
20

10

1
-0.15 -0.10 -0.05 0.00 0.05 0.10 0.15
Residual

Fig. 13. Developed response surface models normal probability plot for surface Fig. 14. Percentage error of power consumption model and surface roughness
roughness. model.
C. Ahilan et al. / Applied Soft Computing 13 (2013) 15431551 1551

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[16] R.A. Fisher, Statistical Method for Research Worker, Oliver & Boyd, London,
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References Dr. C. Ahilan is Professor and Head in the Department of Mechanical Engineering
Oxford Engineering College, Tiruchirappalli, 620009 Tamil Nadu, India. He received
[1] M.C. Shaw, Metal Cutting Principles, Oxford University Press, New York, 1984. his BE in Mechanical engineering from the PSG College of Technology, India in 1997
[2] G. Boothroyd, W.A. Knight, Fundamentals of Machining and Machine Tools, and MTech in manufacturing technology from the National Institute of Technology
Marcel-Dekker, New York, 1989. Tiruchirappalli in 2007. He has worked as a Research Assistant in the Department
[3] P.G. Benardos, G.C. Vosniakos, Predicting surface roughness in machining: a of Production Engineering, National Institute of Technology Tiruchirappalli. He has
review, International Journal of Machine Tool and Manufacturing 43 (2003) published 5 papers in international conferences, and 4 international journals. His
833844. research area includes intelligent industrial energy management systems.
[4] I.P. Arbizu, C.J.L. Perez, Surface roughness prediction by factorial design of Dr. Somasundaram Kumanan is a Professor and Dean in the Department of Pro-
experiments in turning processes, Journal of Materials Processing Technology duction Engineering at National Institute of Technology, Tiruchirappalli, India. He
143144 (2003) 390396. obtained his Doctorate Degree in Manufacturing Management from Indian Insti-
[5] M.P. Groover, Fundamentals of Modern ManufacturingMaterials Processing tute of Technology, Madras, India. He has published 50 papers in international
and Systems, Prentice-Hall, Englewood Cliffs, 1996. conferences and 100 international journals. His research interests are Intelligent
[6] J. Kopac, S. Sali, Tool wear monitoring during the turning process, Journal of Manufacturing Systems, Modeling, Simulation and Optimization of Manufacturing
Materials Processing Technology 113 (2001) 312316. Systems.
[7] K. Ihsan, K. Mustafa, C. Ibrahim, S. Ulvi, Determination of optimum cutting
parameters during machining of AISI 304 austenitic stainless steel, Materials Dr. N. Sivakumaran is an Assistant Professor in the Department of Instrumen-
and Design 25 (2004) 303305. tation and Controls Engineering, National Institute of Technology Tiruchirappalli,
[8] M.A. Xavior, M. Adithan, Determining the inuence of cutting uids on tool India. He received his BE in electronics and instrumentation from Bharathidhasan
wear and surface roughness during turning of AISI 304 austenitic stainless steel, University, India, ME in process control and instrumentation engineering from
Journal of Materials Processing Technology 209 (2009) 900909. Annamalai University, India and PhD in the area of process control and instrumen-
[9] I.A. Chouhury, M.A. El Baradie, Surface roughness in the turning of high strength tation from National Institute of Technology Tiruchirappalli. He has published more
steel by factorial design of experiments, Journal of Materials Processing Tech- than 22 papers in national/international conferences, 13 international journals and
nology 67 (1997) 5561. 3 national journals. His teaching and research interests are in the areas of Process
[10] J.P. Davim, A note on the determination of optimal cutting conditions for surface control and Control systems.
nish obtained in turning using design of experiments, Journal of Materials
Processing Technology 116 (2001) 305308. Dr. J. Edwin Raja Dhas is a Professor and Head in the Department of Automo-
[11] D.I. Lalwani, N.K. Mehta, P.K. Jain, Experimental investigations of cutting bile Engineering at Noorul Islam University, India He obtained his Doctoral Degree
parameters inuence on cutting forces and surface roughness in nish hard from National Institute of Technology, Tiruchirappalli, India. He has published more
turning of MDN250 steel, Journal of Materials Processing Technology 206 than 22 papers in national/international conferences and 15 international/national
(2008) 167179. journals. His research interests are Non traditional simulation and optimization of
[12] D.C. Montgomery, Design and Analysis of Experiments, 4th ed., Wiley, New Manufacturing Systems.
York, 1997.

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