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International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering Vol:4, No:2, 2010
International Science Index, Mechanical and Mechatronics Engineering Vol:4, No:2, 2010 waset.org/Publication/5338
I. INTRODUCTION
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International Science Index, Mechanical and Mechatronics Engineering Vol:4, No:2, 2010 waset.org/Publication/5338
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International Science Index, Mechanical and Mechatronics Engineering Vol:4, No:2, 2010 waset.org/Publication/5338
Machine tool
Work materials
Cutting tool
Geometry
Tool holder
Cutting parameters
Cutting velocity, V
Feed rate, f
Depth of cut, d
MQL supply
Environment
TABLE I
EXPERIMENTAL CONDITIONS
: Lathe Machine(China), 7.5 kW
: Medium Carbon Steel
: Uncoated Carbide, (p-30 grade), Sandvik
: -6,-6,6,15,75,0.8 mm
: PSBNR 2525 M12 (ISO specification), Widia
: 66 and 258 m/min
: 0.10 and 0.20 mm/rev
: 1.0 and 1.5 mm
: Flow Rate 150 ml/hr, Air Pressure 23 bar, Oil
Pressure 25 bar
: MQL (VG-68 Cutting oil)
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International Science Index, Mechanical and Mechatronics Engineering Vol:4, No:2, 2010 waset.org/Publication/5338
(1)
Ra =
1 n
Yi
n i =1
(2)
1L
Y( x ) dx ,
L0
Cutting speed
Feed rate
Depth of cut
Machining time
Artificial
Neural
Network
Fig. 5 Schematic diagram of ANN for tool wear and surface roughness
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International Science Index, Mechanical and Mechatronics Engineering Vol:4, No:2, 2010 waset.org/Publication/5338
Feed
rate
,
f
T = Maximum principal flank wear, VM
Pi =
i
Depth of cut, d
Average auxiliary flank wear, VS
Machining time, t c
Average surface roughnes, R a
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10
10
International Science Index, Mechanical and Mechatronics Engineering Vol:4, No:2, 2010 waset.org/Publication/5338
-1
10
-2
10
-3
10
-4
10
-5
10
20
40
60
119 Epochs
80
100
Bias,
Bias,
VB
V
f
VS
tc
Ra
Input layer
Output layer
Hidden layer
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1/ 2
(((
) )
j t j o j / t j 100
MEP =
p
(3)
t o 2
j
j j
R2 =1
j oj 2
APE(%) =
where,
t
O
RMSE
MEP
APE
R2
P
j
( )
(4)
(5)
(6)
: Target value
: Output value
: Root mean squared error
: Mean error percentage
: Absolute percentage of error
: Coefficient of determination/ absolute fraction of
variance
: Number of patterns
: Processing elements
TABLE II
TEST CUTTING CONDITIONS
Test cutting conditions [V (m/min), f (mm/rev), d (mm), tc (min) ]
1
[66, 0.10, 1.5, 0.5]
2
[66, 0.10, 1.00, 1.0]
3
[66, 0.10, 1.50, 5]
4
[258, 0.20, 1.00, 2.0]
5
[258, 0.20, 1.50, 1.50]
6
[66, 0.10, 1.00, 8.0]
7
[66, 0.10, 1.00, 22]
8
[66, 0.10, 1.50, 24]
9
[258, 0.20, 1.00, 11]
10
[258, 0.20, 1.50, 10,]
Average principal flank wear, VB, m
1
2
RMSE = t j o j
p j
350
ANN results
Experimental resuls
300
250
200
150
100
50
0
10 11
400
ANN resuls
Experimental results
350
300
250
200
150
100
50
0
10 11
(a) average principal flank wear (b) maximum principal flank wear
350
4.0
ANN results
Experimental results
300
ANN results
Experimental resuls
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International Science Index, Mechanical and Mechatronics Engineering Vol:4, No:2, 2010 waset.org/Publication/5338
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3.0
200
2.5
150
2.0
100
1.5
50
0
10 11
1.0
10 11
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International Science Index, Mechanical and Mechatronics Engineering Vol:4, No:2, 2010 waset.org/Publication/5338
TABLE III
R2 AND MAPE VALUES BETWEEN THE NETWORK PREDICTIONS AND THE
EXPERIMENTAL VALUES
Training performance
Hidden
1
1
1
layer
Hidden
30
20
25
neurons
VB ( Average principal flank wear)
R2
0.9998 0.9998 0.9998
MAPE
0.0029 0.0061 0.0138
VM (Maximum principal flank wear)
R2
0.9999 0.9999
0.9999
MAPE
0.0044 0.0051
0.0036
VVS (Average auxiliary flank wear)
R2
0.9994
0.9995 0.9994
MAPE
0.0118
0.0096 0.0087
RRa ( Average surface roughness)
R2
0.9996
0.9996 0.9996
MAPE
0.0044
0.0037 0.0082
Object model
Input neuron
Output neuron
Network structure
Network type
Transfer function
Training function
Learning function
Learning conditions
Learning scheme
Learning rule
Input neuron
Output neuron
Sample pattern vector
Number of hidden layer
Neurons in hidden layer
Testing performance
1
1
1
20
25
30
0.9643
2.4635
0.9915
0.3633
0.9907
4.7226
0.9815
0.0348
0.9906
0.3812
0.9855
3.5843
0.9528
2.5265
0.9761
1.6331
0.9745
1.9135
0.8901
4.3964
0.9627 0.8691
4.8069 3.6261
TABLE IV
SUMMARY OF ANN MODEL
: Tool wear and surface roughness
: V, f, d, tc
: VB, VM, VS, Ra
Learning rate,
Momentum constant,
Performance goal/Error goal
Maximum epochs (cycles) set
MSE at the end of training
:
:
:
:
Feed-forward backpropagation
Tansig/ Purelin
Trainlm
Learngdm
:
:
:
:
:
:
:
:
:
:
:
:
Supervised learning
Gradient descent rule
Four
Four
28 (for training), 10 (for testing)
1 (one)
25
0.1
0.5
0.0001
10,000
9.99642E-05
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International Science Index, Mechanical and Mechatronics Engineering Vol:4, No:2, 2010 waset.org/Publication/5338
V. CONCLUSION
One of the primary objectives in machining operation is to
produce product with low cost and high quality. In order to
achieve such an objective, machining economics can be a
significant consideration. Machining economics involves the
optimum selection of machining parameters, e.g. cutting
speed, feed rate, depth of cut and machining time. The
machining parameters directly affect the cost, productivity and
quality of products. A better predictive model can help as to
choose the optimum machining parameters before performing
machining operations. The objective of this work was to
develop an ANN model to predict tool wear and surface
roughness while turning medium carbon steel under MQL
environment.
An ANN model has been developed for prediction of tool
wear and surface roughness as a function of cutting
parameters. The model has been proved to be successful in
terms of agreement with experimental results. The proposed
model can be used in optimization of cutting process for
efficient and economic production by forecasting the tool
wear and surface roughness in turning operations.
The multilayer feed forward network consisting of four
inputs, 25 hidden neurons (tangent sigmoid neurons) and four
outputs (network architecture represented as 4-25-4) was
found to be the optimum network for the model developed in
this study. The back propagation learning algorithm has been
used in the developed feed forward single hidden layer
network. A good performance of the neural network has been
achieved with coefficient of determination (R2) between the
model prediction and experimental values are 0.9915, 0.9906,
0.9761, and 0.9627 in terms of VB, VM, VS and Ra
respectively The MAPE values for those variables are 0.3633,
0.3812, 1.6331 and 4.8069 respectively. These results show
that the ANN model can be used easily for prediction of tool
wear and surface roughness in turning medium carbon steel by
SNMG insert under minimum quantity lubrication
environment. After adopting the Artificial Neural Network
(ANN) model, the MQL system can enable significant
improvement in productivity, product quality and overall
machining economy even after covering the additional cost of
designing and implementing MQL system.
ANN models have emerged as a new promising method for
estimating tool wear and surface roughness in an intelligent
manufacturing system (IMS). These techniques can easily
capture the complex relationship between various process
parameters and can be easily integrated into an existing
manufacturing environment. These techniques has opened up
new avenues for parameter estimation, optimization and online control of manufacturing system and can assist a lot in
computer aided process planning (CAPP).
In this work, input parameters that have been considered to
develop the ANN model are cutting speed, feed rate, depth of
cut and machining time. The work can be further extended
considering more input parameters such as tool-chip interface
temperature, machine vibration, cutting tool geometry,
workpiece composition, workpiece hardness etc. Then the
ANN model to predict tool wear and surface roughness will be
more robust and universally applicable.
ACKNOWLEDGMENT
This research work has been conducted in the department of
Industrial and production Engineering (IPE) in Bangladesh
University of Engineering and Technology (BUET). The
authors would like to acknowledge BUET for providing the
research facilities and funding to carry out the research work
successfully.
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International Science Index, Mechanical and Mechatronics Engineering Vol:4, No:2, 2010 waset.org/Publication/5338
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