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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.
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
This process is called back propagation stage. After all examples are
trained the system will collect adjusted weights according to:
wji = wji
p
Hidden
layers
Input Output
layer layer
Cutting Speed
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
Evaluation of
Network Weight For each particle, calculate the output of neural network and error
objective
Matrix function
Yes
Cross over
Store the newly
Error(new weights) generated weights in
< Error(pBest) pBest
Mutation
No
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
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)
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
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)
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
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.
Table 5
Analysis of variance analysis for surface roughness.
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
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)
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
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.
Power consumption (W) Surface roughness (m) Power consumption (W) Surface roughness (m)
+ 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
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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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.