Original Paper

Measurement and Control

1–15
Modeling and optimization of Ó The Author(s) 2020
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DOI: 10.1177/0020294020925842

INCONEL-800 super alloy considering journals.sagepub.com/home/mac

energy, productivity, and quality using

nanoparticle suspended lubrication

Te-Ching Hsiao1, Ngoc-Chien Vu1,2 , Ming-Chang Tsai1,

Xuan-Phuong Dang2 and Shyh-Chour Huang1

Abstract
Inconel-800 super alloy is a newly difficult-to-cut material. To improve the cutting conditions for this metal, sustainable
methods in which minimum quantity lubrication enhanced with suspended nanoparticle were employed. This work also
aims to model the relationship between process parameters (cutting speed, feed per tooth, depth of cut, and corner
radius of cutting tool) and machining responses (surface roughness, specific cutting energy, cutting power, and material
removal rate) using orthogonal array design of experiment and response surface methodology. Non-dominated sorting
genetic algorithm was used to solve the multi-objective optimization problems in terms of energy, productivity, and qual-
ity of the machining process. The results indicate that the application of the response surface methodology model in
combination with non-dominated sorting genetic algorithm is appropriate for this study due to the goodness of fit of
response surface methodology and the global optimum solution of genetic algorithm. Because multi-objective optimiza-
tion gives multiple solutions, Pareto plot and data mining are employed to support the selection of process parameters
that can save time and cost and increase energy efficiency, meanwhile, simultaneously improve productivity and surface
quality. The research results show that the specific cutting energy and energy consumption can be reduced up to 20.2%
and 6.4%, respectively.

Keywords
Minimum quantity lubrication, nanofluid, specific cutting energy, energy consumption, machining optimization

Date received: 3 January 2020; accepted: 18 April 2020

Introduction machinability to achieve the best performance.5 Some

Super alloys play an important role in the manufactur-
ing industry. A very important super alloy employed in
the aerospace industry is a nickel–iron–chromium alloy,
namely Inconel 800. Besides aerospace, this super alloy
is also used in the defense, heat exchanger, automotive,
and marine industries. The Inconel-800 super alloy has
excellent properties (Table 1) than other materials con-
sisting of eminent toughness, high tensile strength, good
corrosion resistance, and high-temperature strength;1–3
however, this super alloy is a difficult-to-cut material.4
Therefore, for machining the Inconel-800 super alloy,
consideration of researchers’ finding is important
because of the alloy’s poor thermal conductivity, hot
hardness, and chemical reaction with cutting tools.4 A
feasibility study for the machining of super alloys
involves the use of auxiliary equipment to enhance
studies include the application of laser-assisted machin-
ing (LAM).6,7 This method makes use of a laser beam
to increase the machinability of super alloys. However,
the cost of investing in equipment for LAM is quite
high. In addition, the laser beam can be dangerous for
machine operators. Because of that, this method cannot
be widely implemented. Other works have investigated
1
Department of Mechanical Engineering, National Kaohsiung University
of Science and Technology, Kaohsiung
2
Mechanical Engineering Faculty, Nha Trang University, Nha Trang,
Vietnam
Corresponding author:
Shyh-Chour Huang, Department of Mechanical Engineering, National
Kaohsiung University of Science and Technology, 415 Chien-Kung Rd,
Kaohsiung 80778.
Email: shuang@nkust.edu.tw

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open-access-at-sage).
2 Measurement and Control
some sustainable cooling and lubrication techniques,
for instance, the minimum quantity lubrication (MQL)
technique,8 cryogenic technique,9 and nanofluid MQL
technique.4
The approach of nanofluids-assisted MQL is a high-
grade technique that is being accepted by some model
manufacturing industries due to its good characteris-
tics.10–13 The approach is capable of overcoming the
disadvantages of dry machining and machining with a
flood or MQL technique. Dry machining is economical
as well as ecological; however, in dry machining, it is
difficult to cut super alloy materials like Inconel-800
due to several limitations. It is the cause of poor surface
quality and a higher cutting temperature leading to
reduced tool life.2,11,14 Cutting fluids in flood form can
reduce the temperature in the cutting zone, but the use
of a large amount of cutting fluid causes an increase in
costs and many problems for human health.15 MQL is
considered to be a cooling technique that replaces con-
ventional lubrication methods with a very small quan-
tity of fluid at a flow rate of 50–500 mL/h under the
required high air pressure varying from 2 to 6 bar.15–18
The MQL technique contributes to the reduction of the
amount of lubricant, decreasing product costs, as well
as increasing machining performances. The fluid used
in the MQL technique should be decomposable and
eco-friendly. Therefore, the MQL technique is an eco-
nomical and environmentally friendly lubrication tech-
nique.2,18–21 However, since the heat transfer coefficient
of cutting fluid, such as oil, water, and an ethylene gly-
col mixture, is low, the temperature dissipation in the
cutting zone of the lubrication is limited. The so-called
nanofluids can enhance thermal conductivity up to
twofold.22 Several other studies also illustrate this.23–26
Furthermore, the addition of nanoparticles into the cut-
ting fluid also increases the surface quality, lessens the
cutting force, diminishes friction between two contact
surfaces, and extends the tool life.27–32 Therefore, this
work focuses on using the MQL technique enhanced by
nanoparticle suspended lubrication when end milling a
new nickel-based alloy.
Energy reduction in the modern manufacturing
industry is an essential requirement not only because
the energy source in the world is gradually being
exhausted but also because reducing energy consump-
tion minimizes disadvantages to the living environ-
ment.19,33 Considering energy consumption in the
manufacturing industry, especially for machining tools,
the milling process can be separated into two levels:
machine enhancements and process parameter optimi-
zation.34 The first approach is sometimes not feasible;
the second is much more possible because it not only
saves in cost but also demands less effort. Therefore,
saving energy consumption by optimizing technological
parameters in processing is an attractive concern for
many researchers.
Specific cutting energy (Uc) is a quantity to evaluate
the impact of the cutting process on the environ-
ment.35,36 Uc is the energy required to remove a
quantity of material in a unit of time. Warsi et al.
develop and analyze Uc-based process data and map
facilitates high-speed machining of Al 6061 T6 alloy.37
Jang et al.19 also research Uc to accomplish environ-
mentally conscious manufacturing (ECM) in the MQL
milling process. Campatelli et al. also focus on the
worldwide diminution of environmental impacts by
minimizing the power consumption including energy,
specific energy, and total energy using response surface
methodology (RSM) in the milling of carbon steel.38
The literature review shows that researches on mod-
eling and optimization of process parameters for saving
energy in the field of metal processing draw particular
attention to the manufacturing industries. The models
usually used to render the relation between input para-
meters and technological responses are RSM, artificial
neuron network (ANN), the Kriging model, and radial
basis function (RBF). Among them, RSM is most com-
monly employed by researchers in engineering because
of its flexibility and reliability.34,39–41 After modeling
the relationship between process parameters and
machining responses, an optimization algorithm will be
applied to solve the optimization problems. Some stud-
ies use the Taguchi method for optimization of energy
consumption. For example, Camposeco-Negrete et al.
used the Taguchi method to determine the level of three
factors that affects energy consumption with a constant
material removal rate.42 However, the limitations of the
Taguchi method do not warrant a ‘‘real optimal’’ solu-
tion because it only addresses the discrete control fac-
tor.43 Similarly, Gray relational analysis (GRA) does
not offer a ‘‘real optimal’’ solution.44 It is also optimal
to determine the best level of the factor. Recently, the
evolutionary optimization algorithm was applied in
engineering as the particle swarm optimization (PSO),
non-dominated sorting genetic algorithm (NSGA-II),
and archive-based micro genetic algorithm (AMGA).
Jang et al.19 used ANN couple PSO to optimize the sin-
gle objective that is specific cutting energy. However,
optimizing for a single objective function is not realistic
in metal cutting. Nguyen employed the Kriging model
and AMGA to optimize dry milling in terms of machin-
ing energy, surface quality, and production rate.45 Park
et al.34 also optimized energy efficiency using the hybrid
RSM and NSGA-II to determine the best solution for
specific cutting energy and energy efficiency. It can be
seen that the modeling and optimization for energy effi-
ciency in the nanofluid MQL machining process are
still of interest.
Optimization techniques applied to engineering are
diverse and can be classified into two main groups: tra-
ditional and advanced optimization. Conventional
optimization techniques can be involved Taguchi
method, GRA, and RA coupled with RSM. The
advanced optimization techniques consist of PSO,
NSGA-II, AMGA, teaching-learning-based optimiza-
tion (TLBO). The advanced optimization techniques
are more robust than conventional ones because they
base on global search algorithm and can solve both
Hsiao et al. 3

Table 1. Mechanical properties of Inconel 800 alloy.

Temperature (°C) Tensile strength (MPa) Yield strength (MPa) Elongation (%) R.A. (%)

27 448–549 172–226 30–48 76

Table 2. Summary of conventional and advanced optimization techniques.

Authors Optimization Application areas Remarks

techniques

Conventional optimization
techniques
Pramanik et al.,46 Taguchi WEDM, fused filament Taguchi method and ANOVA can be proved the
Singh et al.,47 fabrication, compliant significant impact of processing conditions of
Vu et al.48 wire EDM.
The results of Taguchi method are good
agreement with Weibull analysis.
Taguchi method is capable of evaluating the
optimal value with acceptable deviation error by
7.15%.
Yan and Li44 GRA Milling GRA is a strong tool for multi-objective
optimization in machining to optimize cutting
parameters.
Gajalakshmi et al.49 GRA coupled Dry sliding wear GRA couple with RSM in optimizing dry sliding
with RSM wear parameters can reduce wear, coefficient of
friction, and frictional force.
Advanced optimization
techniques
Ravichandran and TLBO Position errors in TLBO optimization it can be significantly
Uthirapathy50 CNC machine improved of R2 for X, Y, Z axes are 1%–2.6%,
1%–14.3%, and 10.3%–71.1%, respectively
Gülhan and Erbatur51 GA Robotics The application of GA optimization technique
has improved higher results than previous
studies
Kavitha and Venkumar52 SSO-GA Job shop scheduling Social spider optimization in conjunction with
GA (SSO-GA) is effectively controlled to
diminished makespan time compare with other
hybrid of optimization algorithm
Prakash et al.53,54 NSGA-II PMEDM machining NSGA-II was proposed to enhance the finding of
the optimal technological responses
simultaneously
Iqball et al.,55, Prakash et al.,56 PSO Wind turbine system, PSO was used for stabilizing the system more
Prakash et al.57 EDM machining quickly and effectively
PSO technique gives the optimal input
parameters and captures the influence of
machining parameters. PSO improved the MRR
and Ra respect to the worst case without
optimization by 14.89% and 15.94%, respectively
Liu and Zhang58 LS-SVM Shield machine Parallel cooperative particle swarm optimization-
combine with PSO partial least squares support vector machine
significantly enhanced in modeling capability and
precision
Prakash et al.59 Hybrid PSO-SA Gas tungsten arc Hybrid PSO-simulated annealing algorithm is
welding capable of enhancing significantly of the
confidence interval by 95%

WEDM: wire electrical discharge machining; ANOVA: analysis of variance; GRA: gray relational analysis; RSM: response surface methodology; TLBO:
teaching-learning-based optimization; CNC: computer numerical control; GA: genetic algorithm; SSO-GA: social spider optimization–genetic
algorithm; NSGA-II: non-dominated sorting genetic algorithm; PMEDM: powder mixed electric discharge machining; PSO: particle swarm
optimization; MRR: material removal rate; LS-SVM: least-squares support vector machine; PSO-SA: swarm optimization–simulated annealing.

constrained and unconstrained multi-objective optimi-
zation. In addition, advanced optimization techniques
can effectively solve complex optimization problems in
which the global optimum result is guaranteed. The
summaries of the literature review of conventional
and advanced optimization techniques that were
used in the engineering field are shown in Table 2.
The application of a suitable optimization tech-
nique fosters the optimization process and gives a
reliable optimal solution.
4 Measurement and Control
Table 3. Chemical composition (wt%) of Inconel-800 super alloy.
Element Ni Cr Fe
% weight 30.0–35.0 19.0–23.0 46.99
Figure 1. Cutting tool for experiments.
According to the aforementioned literature reviews,
it can be seen that overcoming the difficulties in
machining in the new nickel-based alloy that has high
applicability remains a big challenge. Furthermore, the
application of MQL nanolubrication to enhance the
machinability of the Inconel-800 super alloy, as well as
multi-objective optimization to the proper selection of
the cutting condition in terms of cutting energy reduc-
tion, high productivity, and good quality, is essential
for researchers. Therefore, with this aim, this paper will
perform multi-objective optimization of milling for
Inconel-800 using carbon nanotube nanoparticle-based
CT232 cutting oil in MQL in order to obtain the effi-
ciency of energy, a good surface finish, and high
productivity.
To obtain the optimal machining conditions for the
milling of Inconel-800 alloy, the cutting parameters
(cutting velocity, feed rate, depth of cut, and corner
radius of cutting tool) which affect the technological
responses (specific cutting energy, energy consumption,
and surface roughness) should be figured out scientifi-
cally. To solve the research problem, an RSM model is
employed to render the relationship between the cutting
parameters and technological responses. Furthermore,
the NSGA-II technique, an evolutional algorithm, will
be utilized to solve the multi-objective optimization in
this work. The remainder of this paper will present in
detail the systematic research procedure, experimental
setup, data processing, modeling, and process para-
meter optimization. Subsequently, the results and dis-
cussion will be shown, and finally, the conclusions and
major contributions will be made.
Materials and methods
The workpiece used in the experiment is made of an
Inconel-800 super alloy, with the chemical composition
C Al Ti Ti + Al Mn
0.1 max 0.5 0.15–0.60 1.01 1.5 max
as tabulated in Table 3. A milling machine, namely, the
Victor Vertical Machining Center 4, was utilized in this
work. The type of milling operation is end milling (slot
milling) and the type of depth of cut is axial depth of
cut. The radial depth of cut was kept constant that
equal to the diameter of the cutting tool. Workpiece
dimensions were 225 mm (L) 3 100 mm (W) 3 60 mm
(H) with the 100 mm dimension being the cutting
length. The tool holder, namely a CoroMill R390
square shoulder milling cutter with two flutes, was used
to perform all experiments. The inserts were entitled
R390-11 T3 with three kinds of radii of noses consist-
ing of 0.4, 0.8, and 1.2 mm. The diameter of the milling
tool was F16 mm (Figure 1).
Experiments were processed under minimum lubri-
cation conditions with a flow rate of MQL oil, angle of
nozzle, air pressure, and distance of nozzle parameters
fixed as 100 mL/h, 60°, 3 kg/cm2, and 20 mm, respec-
tively. Multi-walled carbon nanotube (MWCNT) with
particle sizes smaller than 30 nm was dissolved into the
cutting oil CT 232. This cutting oil can increase accu-
racy, the efficiency of cost and energy, and tool life. It
also has higher stability and difficult to deterioration.
Specifications of CT232 cutting oil are described in
Table 4. The percent of MWCNT in the cutting oil was
0.5 vol%. The selection of nanoparticle concentrations
is based on the initial experiments of this work, and the
reference of related studies.60,61 The solution was stir-
red continuously using a magnetic stirrer for about
48 h. MWCNT was chosen because it has higher ther-
mal conductivity (300 W/m K) than other nanoparti-
cles.62 The machining environment of the experiments
is shown in Table 5.
Regarding the design of experiment (DOE), this
work designates four main controllable variables,
including cutting velocity (vc), feed per tooth (fz), depth
of cut (ap), and corner radius (mm). The values of the
Hsiao et al. 5

Table 4. Specifications of CT232 cutting oil.

Color Viscosity cSt. at 40°C Flash point (°C) Fatty (%) CL (%) Stability and resistance Copper corrosion, 100°C, 1 h

Yellow 26 200 11 9.6 Good 1

Table 5. Machining environment of experiments. Table 6. The factors and their levels.

1 Machine Victor Vertical Machining Center 4 Factor Units Levels

2 Workpieces Material: Inconel 800
Dimensions: 225 mm (L) 3 100 mm 1 2 3
(W) 3 60 mm (H)
3 Cutting tools Diameter: F16 mm Cutting velocity (vc) m/min 90 120 150
CoroMill R 390 square shoulder Feed per tooth (fz) mm/tooth 0.03 0.06 0.09
milling cutter (R390-016A16-11L) Depth of cut (ap) mm 0.4 0.7 1.0
Insert: R390-11 T3 04,08,12 Corner radius (r) mm 0.4 0.8 1.2
4 Cooling condition MQL with MWCNT nanofluid
Distance of nozzle: 20 mm
Air pressure: 3 kg/cm2
Angle of nozzle: 60° and four-wire electrical circuits of power analyzers were
Flow rate: 100 mL/h connected with suitable direct to get signals of voltage
Cutting oil: Super E.P. CT232 and current. These signals were processed through
MWCNT with size \ 30 nm.
Concentration in lubrication: 0.5% Lutron data acquisition software installed on the com-
puter. From there, the values of power consumption
MQL: minimum quantity lubrication; MWCNT: multi-walled carbon were determined. The cutting force was estimated by a
nanotube; CL: Chlorine. piezoelectric and a Vishay 6100 scanner. The signals
were collected on the computer and processed by
installed software. The MRR (mm3/min) in cutting pro-
input parameters are divided into three levels in which cess be calculated from equation (1)
the levels are chosen based on the cutting tools recom-
mendation and the experience of operators. The factors ap  ae  vc  fz  z  1000
MRR = ð1Þ
and their levels are presented in Table 6. Figure 2 is sys- 3:14  d
tematic procedure of modeling and optimization of where ae is the width of cut (mm), z is the flute of cut-
machining parameters for this work. To reduce the ter, and d is diameter of cutting tool (mm). The details
number of experiments and to save experimental costs, of the experimental setup are illustrated in Figure 3.
the orthogonal array design is assumed to generate a Generating energy in a certain way will adversely
set of 27 experiments, as shown in Table 7. affect the environment, so (Uc) is often adopted to
The machining responses which depend on the cut- assess the influence of machining on the environ-
ting parameters are surface roughness (Ra), specific cut- ment.19,63 The magnitude of the specific cutting energy
ting energy (Uc), cutting power (Pc), and material (Uc) is calculated as19
removal rate (MRR). The Mitutoyo SJ-400 surf-test
instrument was employed to measure the surface rough- F c  vc
Uc = ð2Þ
ness. The voltage and current were measured by a MRR
Lutron 3 Phase Power Analyzer DW-6092. Three-phase where Fc denotes the total cutting force.

Figure 2. Systematic procedure of modeling and optimization of machining parameters.

6 Measurement and Control

Table 7. DOE and the results of experiment.

No. Machining parameters Machining responses

vc (m/min) (ap) (mm) fz (mm/tooth) r (mm) Ra (mm) Pc (W) Uc (J/mm3) MRR (mm3/min)

1 90 0.4 0.03 0.4 0.206 636.8 0.926 687.9

2 150 0.4 0.09 0.4 0.507 817.6 0.238 3439.5
3 120 0.4 0.06 0.4 0.351 727.2 0.396 1834.4
4 120 0.7 0.03 0.4 0.342 724.0 0.451 1605.1
5 150 0.7 0.06 0.4 0.368 867.2 0.216 4012.7
6 90 0.7 0.09 0.4 0.434 815.2 0.226 3611.5
7 150 1.0 0.03 0.4 0.441 812.8 0.284 2866.2
8 90 1.0 0.06 0.4 0.450 804.8 0.234 3439.5
9 120 1.0 0.09 0.4 0.599 1011.2 0.147 6879.0
10 120 0.4 0.03 0.8 0.201 659.2 0.719 917.2
11 150 0.4 0.06 0.8 0.297 766.4 0.334 2293.0
12 90 0.4 0.09 0.8 0.363 712.0 0.345 2063.7
13 150 0.7 0.03 0.8 0.313 776.8 0.387 2006.4
14 90 0.7 0.06 0.8 0.342 734.4 0.305 2407.6
15 120 0.7 0.09 0.8 0.504 850.4 0.177 4815.3
16 90 1.0 0.03 0.8 0.453 698.4 0.406 1719.7
17 120 1.0 0.06 0.8 0.531 856.8 0.187 4586.0
18 150 1.0 0.09 0.8 0.620 1053.6 0.123 8598.7
19 150 0.4 0.03 1.2 0.164 728.0 0.635 1146.5
20 90 0.4 0.06 1.2 0.224 662.4 0.481 1375.8
21 120 0.4 0.09 1.2 0.383 732.8 0.266 2751.6
22 90 0.7 0.03 1.2 0.303 660.0 0.548 1203.8
23 120 0.7 0.06 1.2 0.400 790.4 0.246 3210.2
24 150 0.7 0.09 1.2 0.500 927.2 0.154 6019.1
25 120 1.0 0.03 1.2 0.504 778.4 0.339 2293.0
26 150 1.0 0.06 1.2 0.504 957.6 0.167 5732.5
27 90 1.0 0.09 1.2 0.541 954.4 0.162 5159.2

DOE: design of experiment; MRR: material removal rate.

Figure 3. The details of the experimental setup.

To demonstrate the relationship between the paper uses RSM model that is widely employed for
machining parameters and technological responses, this modeling and analyzing in mechanical engineering. In
Hsiao et al.
Figure 4. Framework of NSGA-II methodology to optimize
cutting parameters.
this model, the second order is utilized to approximate
the response as follows
X
k X
k k1 X
X k
c = c0 + ci Xi + cii X2i +
i=1 i=1 i=1 j=i+1
where (c0) is the constant, and (ci), (cii), and (cij) are
coefficients. (Xi) and (Xj) are the variables. (e) is the
random error of the experiment.
Afterward, an evolutional multi-objective opti-
mization algorithm frequently used to optimize in
mechanical engineering is the NSGA-II applied to
solve the optimization problems given by the
author. The framework of NSGA-II methodology
to optimal cutting parameters in this paper is
shown in Figure 4.
The optimal objective of this work is to minimize
energy consumption and maximize surface quality or
maximize machining productivity (material removal
rate). Therefore, two scenarios are considered:
The first scenario, we minimize Uc and Ra.
The second scenario Pc is minimized and MRR is
maximized with constraint of surface roughness.
Figure 5. Confirmation of the suitability of RSM model estimated by the coefficient R2.
7
Results and discussion
The data for the physical experimental results in this
paper were collected and analyzed to render a relation-
ship among process parameters and surface roughness,
specific cutting energy, and cutting power. The results
of 27 experiments based on the Taguchi orthogonal
array are presented in Table 6. As mentioned in the
‘‘Materials and methods’’ section, RSM was employed
to capture the influence of input parameters on techno-
logical responses based on these data.
The authenticity of the RSM model to the experi-
mental data is displayed by the coefficient of determina-
tion for regression analysis (R2). The coefficient values
of R2 for Ra, Pc, and Uc were 0.959, 0.953, and 0.970
respectively. It can be seen that the coefficient values of
R2 for the RSM model are greater than 0.9 and are
shown in Figure 5. Therefore, it can be concluded that
the Kriging model is an appropriate model.
Figures 6, 8, and 9 depict the three-dimensional (3D)
graph showing the influence of the input parameters
(vc, ap, fz, r) on the machining response (Ra, Pc, Uc),
cij Xi Xj +e
respectively. Figure 6 shows the influence of the process
parameters on the surface roughness. From this figure,
it can be inferred that Ra increases with a correspond-
ð3Þ ing rise in ap and fz. On the other hand, increasing vc
and r leads to a decrease in Ra. It can be explained that
machining at lower cutting velocity causes a built-up
edge (BUE) phenomena on the cutting edge of the cut-
ting tool. The BUE is formed which harms the cutting
edge, lowering the surface roughness quality. When the
corner radius ranges from 0.4 to 1.2 mm, the quality of
the surface roughness is markedly improved. This phe-
nomenon helps us understand that increasing the cor-
ner radius leads to a rising plowing effect that expands
the material side flow on the surface finish.64 Cutting
with a large ap increases the cutting force and cutting
temperature. An increase in fz causes the expansion of
the furrows which are generated by the rotation of the
cutting tool on the machining surface. These have led
to reduced surface roughness quality. The results agree
well with previous studies.2,65
Some experiments on the wear of inserts with differ-
ent corner radii as the levels of the corner radius are
performed. The results indicated that the higher the
8 Measurement and Control
Figure 6. Surface roughness versus machining parameter.
Figure 7. Optical micrographs of worn inserts: (a, b) R = 0.4 (mm), (c, d) R = 0.8 (mm), and (e, f) R = 1.2 (mm).
corner radius, the greater the wear of inserts. Figure 7
shows that abrasion phenomena such as crater wear or
flank wear in milling inserts are increased as corner
radius increases. This is in line with the metal cutting
theory.
It is found from the 3D graph shown in Figure 8 that
increasing the feed rate, depth of cut as well as the cor-
ner radius creates an increase in cutting power. This can
be interpreted as follows. An increase in feed rate and
depth of cut results in an enlargement in the MRR per
unit of time, which means that the cutting force or cut-
ting power is raised. Our results are in line with previ-
ous works.40,66
Figure 9 indicates the effect of the machining process
on specific cutting energy (Uc). It can be seen that Uc
increases as ap and fz decrease. This can be explained by
the fact that the energetic effect of the machined volume
increment is greater than that of the cutting energy.19
However, machining with larger ap and fz values leads
to an increased cutting force. This causes a reduced tool
life, so these parameters need to be limited. Figure 9
also shows that vc and r have little effect on Uc.
The specific cutting energy Uc of Inconel-800 super
alloy is compared with other works.1,4,8 The compari-
son shows that Uc of milling and turning is little differ-
ent (Uc range from 1.16 to 1.86 J/mm3 for turning
compared to 0.12–0.93 J/mm3 for milling). The reason
for these slight differences is due to the difference
between the cutting movement and geometry of the
milling and turning tools. In addition, the specific cut-
ting energy Uc in this work is smaller than that of
Gupta et al.1 because of the contribution of MQL
lubrication with MWCNT. This technique has a good
lubrication effect so it diminishes the friction leading to
a reduction in cutting force. It can be concluded that
our research results are reliable. Our study is intended
as a contribution to demonstrate the superiority of
MWCNT for MQL lubrication.
Hsiao et al.
Figure 8. Cutting power versus machining parameter.
Figure 9. Specific cutting energy versus machining parameter.
Figure 10. The global effect of process parameters on (a) Ra, (b) Pc, and (c) Uc (%).
Figure 10 presents the global effects (or can be called
the main effect) of process parameters on the technolo-
gical response. The values on the horizontal axis of
Figure 10 are calculated by percentage (%). As seen in
Figure 10, the greatest effects on Ra, Pc, and Uc are
depth of cut, cutting velocity, and feed per tooth,
respectively. Following that, in terms of influence to
technological response, Ra, Pc, Uc are feed per tooth
and depth of cut. The rest of the parameters also have
significant or little effect on the machining response.
Regression equations that were determined based on
RSM model for surface roughness, cutting power, and
specific cutting energy are presented in Table 8.
After modeling using the RSM model, three avail-
able statistical regression equations show the relation-
ship between input parameters and output parameters.
Based on these equations, multi-objective optimization
was employed to find the optimal solutions for
9
scenarios presented under Materials and methods. The
NSGA-II algorithm is implemented to find the optimal
solution for this problem. The parameters of the
NSGA-II were recorded as follows:
Population size = 20;
Number of generations = 50;
Crossover probability = 0.9;
Crossover distribution index = 10;
Mutation distribution index = 20.
What are the optimal solutions of machining para-
meters that minimize Uc and Ra is a study question for
the first scenario. Figure 11 shows the Pareto plot of
Uc and Ra. The blue points represent the Pareto point,
and the black points show a feasible solution. The
results show that when Ra increases, Uc decreases and
vice versa. It can be seen that these two optimal
10 Measurement and Control

Table 8. Regression equation for surface roughness, cutting power, and specific cutting energy.

Response Regression equations

Ra –0.35 + 0.009 vc + 0.125 ap – 0.875 fz – 0.07 r + 0.20 ap2 + 27.4 fz2 – 0.009 r2 – 0.0003 vc ap + 0.024 vc fz – 0.0003 (4)
vc r – 2.85 ap fz + 0.20 ap r – 0.63 fz r
Pc 633.11 – 0.06vc – 226.64ap – 93.63fz – 131.39r + 0.008vc2 + 48.89ap2 + 888.89 fz2 + 66.67r2 + 0.7vcap – 3.52vc fz – (5)
0.2vcr + 4616.3apfz + 89.93apr – 287.41fzr
Uc 2.98 – 0.01vc – 2.09ap – 24.59fz – 0.34r + 0.60ap2 + 86.48fz2 + 0.05r2 + 0.003 vc ap + 0.03vc fz + 0.0015vc r + 7.22 (6)
ap fz + 0.068ap r + 0.228fz r

the two objectives. Figure 11 also shows the advantages

Figure 11. Pareto front generated by NSGA-II base on RSM
model for the first scenario.
objectives are conflict. The selection of the optimal
value on the Pareto plot depends on the machine oper-
ator making decisions based on the trade-off between
of using NSGA-II optimally over arbitrary options.
For example, for the same Ra = 0.35 (mm), the varia-
tion of Uc (DUc) can be up to 0.268–0.214 = 0.054.
This optimum result is improved over the other result
by around (0.054/0.268) 3 100 = 20.2%.
How can one determine the corresponding input
parameters after selecting the optimal solution? The
answer is shown in Figure 12 which displays data min-
ing to find the optimal process parameters for the first
scenario. The iSight version 5.8 software was used for
data mining. For example, when the optimal solutions
selected in Figure 11 are Uc = 0.453 (J/mm3), and
Ra = 0.213 (mm), the corresponding optimal input
parameters to those response parameters are vc =
149.91 (m/min), fz = 0.044 (mm/tooth), ap = 0.44
(mm), and r = 1.2 (mm).
In the second scenario, multi-objective optimization
problem that minimizes Pc and maximizes MRR while
Ra is the predetermined constraint. Figure 13 shows the
Pareto front generated by the NSGA-II based on the
RSM model for the second scenario. Figure 13(a) and
(b) only shows the Pareto point (optimal solution), and
this demonstrates the variations in Pc and MRR
according to the predefined Ra. When Ra increases, Pc
and MRR increase accordingly. When Ra reaches a

Figure 12. Data mining for finding the optimal process variable for the first scenario.
Hsiao et al.
Figure 13. Pareto front generated by NSGA-II based on RSM model for the second scenario: (a) Surface roughness and cutting
power (b) Surface roughness and material removal rate (c) Cutting power and material removal rate.
constraint value, the optimal solutions for Pc and
MRR still exist but are not conducive to saving energy
consumption. If MRR continues to increase to 4481.2
(mm3/min), Pc will reach 851.33 (W). For MRR, Point
B at the right end of the Pareto front line (Figure
13(b)) is the best optimal point, but for cutting energy,
point A at the end of the slope is the best optimal point
(Figure 13(a)). However, the objective of second sce-
nario is to increase energy efficiency, so the optimum
selection point will not be selected in the DPc1 region.
DPc1 is the magnitude that evaluates the effectiveness
of optimization and the Pareto front and can be calcu-
lated as (851.33 – 752.24)/851.33 = 11.64%.
In Figure 13(c), the variability relationship between
Pc and MRR is shown adequately and accurately. The
objective of the milling process is always machining
with the highest MRR, and the smallest Pc but still
achieving the desired surface quality. However, these
two response parameters (Pc and MRR) conflict with
each other so there should be a compromise to select
the optimal solution. The Pareto point and feasible
optimal solutions are exhibited in Figure 13(c). From
this figure, the milling operator can select the optimal
solution that suits the requirements. As in the first sce-
nario, after selecting the desired technological
11
responses based on the data mining in Figure 14, one is
able to determine the input parameters corresponding
to these technological responses. For example, when
selecting an optimal point through Figure 13(c) with
MRR = 3141.1 (mm3/min) and Pc = 685.67 (W), based
on data mining, the optimal machining parameters can
be determined as vc = 137.44 (m/min), fz = 0.086 (mm/
tooth), ap = 0.4 (mm), and r = 1.2 (mm).
A validation test is conducted based on the above
data; the physical experimental results are shown in
Table 9. From Table 9, it can be seen that the relative
errors between the predicted value and the experimen-
tal value for Ra, Pc are 5.8% and 3.9%. The magnitude
of relative errors is considered acceptable in machining.
This again proves that the application of the RSM
model combined with the NSGA-II optimal algorithm
for this study is very reliable. Besides, this work also
shows machining at an optimal value to compare two
cutting conditions (nanofluid MQL and pure MQL) in
terms of energy efficiency. The results indicate that
machining under nanofluid MQL can improve energy
efficiency compared to using pure MQL. The values of
the effectiveness are shown in Table 10. The surface
roughness reduces 8.4%, and Pc and Uc reduce 6.1%
and 10.5%, respectively. It is clear that MQL with
12
Figure 14. Data mining to find the optimal process variable for the second scenario.
Table 9. Verification result at an optimal value.
Ra Pc
Predicted 0.390 685.67
Real experiment 0.414 713.21
Relative error (%) –5.8 –3.9
nanoparticle not only help to protect environment but
also increase the machining quality and save machining
energy.
Another contribution shown in Figure 13(c) is the
evaluation of the improvement of the application of the
NSGA-II algorithm based on the RSM model com-
pared to the non-application of optimal algorithms. As
seen in Figure 13(c), DPc2 is the deviation that shows
the application and non-application of the optimal
algorithm, at the same MRR = 1517.1 (mm3/min), the
optimal solution for Pc is 732.64 (W), while the arbi-
trary un-optimized solution is 685.65 W. Therefore, the
improvement in energy consumption is (732.64 –
685.65)/732.64 = 6.4%.
Conclusion
This paper addresses the modeling and optimization of
machining parameters in the milling of new nickel-
based alloy in terms of energy, productivity, and qual-
ity. The new point of this work is the combination of
the study of milling of Inconel 800 and the study of cut-
ting of hard-to-cut material in which the emerging
MQL with carbon nanotube suspended lubrication.
The use of MQL with MWCNT increases the tribology
so that reduced the cutting force in specific cutting
energy. In addition, this work applied a multi-objective
optimization technique that facilitates the optimization
Measurement and Control
Table 10. Comparison between the two cutting condition
(nanofluid MQL and pure MQL) at an optimal value.
Uc
Ra Pc Uc
0.259
0.248 Nanofluid MQL 0.414 713.21 0.248
4.3 Pure MQL 0.452 759.45 0.277
Improvement (%) 8.4 6.1 10.5
MQL: minimum quantity lubrication.
process. Pareto plot and data mining methods are pro-
posed in order to select the appropriate trade-off solu-
tion when solving the multi-objective optimization
problem in metal cutting because the objectives are
almost conflicting. The optimal front of Pareto plot
helps the researcher visually determines the best solu-
tion in which the MRR is maximized; meanwhile, the
cutting power is minimized with a predefined constraint
of surface roughness. Some of the main conclusions
drawn by this study are as follows:
1. The application of the multi-objective evolution
algorithm (NSGA-II) in conjunction with RSM
regression model is a robust approach for mod-
eling the relationship between machining para-
meters and technological responses and for
solving machining process parameter optimiza-
tion. The optimal results indicated that the spe-
cific cutting energy could be reduced roughly by
20.2%, while energy consumption could be
reduced by 6.4% compared to arbitrary cases
without applying optimization.
2. The Pareto front plot and engineering data min-
ing generated multi-objective optimization facil-
itate the selection of appropriate machining
parameters to increase the efficient energy
Hsiao et al.
consumption, as well as maximize the material
removal rates.
3. The application of nanofluid MQL with
MWCNT and the optimization enhance the
energy efficiency because the specific cutting
energy is decreased and is in the low range
(below 0.93 J/mm3). This is a significant contri-
bution to environmentally conscious machining.
4. Nanofluid MQL with MWCNT is better than
pure MQL when milling at the optimal point for
the new nickel-based alloy. It not only protects
the environment but also increases technological
responses. The surface roughness, specific cut-
ting energy, and cutting power can reduce 8.4%,
6.1%, and 10.5%, respectively.
5. The research model in this work can be effec-
tively applied as a paradigm to study the optimi-
zation of metal cutting.
The future work will focus intensively on multi-
objective optimization of Inconel-800 in which tool life
and tool wear are included. In addition, the specific
cutting energy map for milling of this kind of material
should be built for a better understanding of this mate-
rial in terms of cutting energy for the study on the
energy efficiency of metal cutting of hard-to-cut
material.
Declaration of conflicting interests
The author(s) declared no potential conflicts of interest with
respect to the research, authorship, and/or publication of this
article.
Funding
The author(s) disclosed receipt of the following financial sup-
port for the research, authorship, and/or publication of this
article: The authors acknowledge and thank the Ministry of
Education of the Republic of China for their partial financial
support of this study under Contract Number E0002B and
the Ministry of Science and Technology of the Republic of
China under Contract Number MOST 108-2622-E-992-009-
CC3.
ORCID iDs
Ngoc-Chien Vu https://orcid.org/0000-0002-4069-2369
Shyh-Chour Huang https://orcid.org/0000-0002-7158-3720
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