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Experimental measurement and

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turning process of Inconel718 superalloy
Article in Measurement March 2015
DOI: 10.1016/j.measurement.2014.11.021

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Measurement 63 (2015) 110

Contents lists available at ScienceDirect

Measurement
journal homepage: www.elsevier.com/locate/measurement

Experimental measurement and optimization of tensile residual

stress in turning process of Inconel718 superalloy
Farshid Jafarian a,, Hossein Amirabadi a, Javad Sadri b,c
a

Department of Mechanical Engineering, University of Birjand, Birjand, Iran

Department of Electrical and Computer Engineering, University of Birjand, Birjand, Iran
c
School of Computer Science, McGill University, Montreal, Quebec, Canada
b

a r t i c l e

i n f o

Article history:
Received 3 August 2013
Received in revised form 26 November 2014
Accepted 27 November 2014
Available online 5 December 2014
Keywords:
X-ray diffraction
Inconel718 superalloy
Residual stress
Intelligent techniques

a b s t r a c t
Generated residual stress in the machining processes is one of the most important factors
which affects signicantly service quality and component life. Inconel718 superalloy is one
of the hard materials utilized widely in the aerospace industries. State of surface residual
stress is a critical problem in the nish machining of Inconel718. Therefore, the aim of the
present study is to estimate and optimize the effect of machining parameters including
cutting speed, depth of cut and feed rate on induced tensile residual stress in the nish/
semi-nish turning process of Inconel718. Machining residual stresses were measured
by X-ray Diffraction (XRD) method. Then, the results were introduced to the intelligent systems (including Articial Neural Network (ANN) and Genetic Algorithm (GA)) to estimate
residual stress at the various machining parameters and optimize the process. Finally, it
was shown that, implemented efcient intelligent techniques in this paper are remarkably
appropriate for machining of Inconel718.
2014 Elsevier Ltd. All rights reserved.

1. Introduction
Induced residual stress in the machining processes is
one of the most important factors which has a signicant
effect on safety and performance of the machined workpieces. Compressive residual stresses in machining
improve some properties of the workpiece such as fatigue
life, creep life and resistance to crack propagation. But the
mentioned properties are impaired by generating tensile
residual stresses [1,2]. This issue plays more critical role
in aerospace industries, where undesirable residual stresses can lead to severe damage in the manufactured
components.
In general, residual stresses in the conventional
machining processes are generated because of three
Corresponding author. Tel.: +98 9357578764; fax: +98 5612502160.
E-mail addresses: farshid.jafarian@ymail.com (F. Jafarian), hamirabadi@
birjand.ac.ir (H. Amirabadi), javad.sadri@cs.mcgill.ca (J. Sadri).
http://dx.doi.org/10.1016/j.measurement.2014.11.021
0263-2241/ 2014 Elsevier Ltd. All rights reserved.

sources including thermal and mechanical loads and metallurgical alterations [3]. The mechanical loads are produced due to the contact and compression between tool
and workpiece, and lead to mechanical plastic deformations on the machined workpiece. These deformations
result in compressive residual stresses. Also, plastic deformations generated by thermal loads are responsible for
generating tensile residual stresses. Besides, intense
increasing of temperature in the near of cutting zone can
leads to a phase transformation on the surface and subsurface of machined workpiece. It can causes tensile or compressive residual stresses because of local volume change
on workpiece [3].
The sources of machining residual stresses are inuenced remarkably by variation of machining conditions.
Thus, different states of residual stress can be induced on
workpiece during the process. This problem becomes more
evident in the machining of difcult-to-cut materials
because severe thermo-mechanical loads are generated

F. Jafarian et al. / Measurement 63 (2015) 110

during the hard cutting [4]. Therefore, it is required to be

performed more investigations in order to evaluate the
effect of machining parameters on residual stress at the
hard cutting.
As one of the difcult-to-cut materials, Inconel718
superalloy has superior properties such as high corrosion
and creep resistance, and maintaining hardness at high
temperatures. Thus, among other nickel based alloys, Inconel718 is the most widely used alloy in the aerospace
industries and in hottest parts of gas turbine engines produced using machining processes. However, these properties are responsible for poor machinability of Inconel718
from different points of view [5,6].
It has been shown that machining of Inconel718 is so
prone to tensile residual stresses on the machined surface
[7,8]. In the following, performed investigations to evaluate residual stress state at turning process of Inconel718
are reviewed. Sadat et al.s study showed that surface tensile residual stress increased when cutting speed changed
from 12 to 96 m/min [9]. Schlauer et al. claimed that
increasing cutting speed from 10 to 810 m/min causes surface residual stresses to tend from compressive to tensile
[10]. In contrast, according to ndings of Pawade et al., a
slight increase in tensile residual stresses was observed
when cutting speed was increased from 125 to 300 m/
min. Also, a signicant change from tensile to compressive
residual stresses was observed when cutting speed was
increased to 475 m/min [11]. They also reported that residual stresses changed from tensile to compressive when
depth of cut increased from 0.5 to 0.75 mm. Effect of some
parameters such as insert shape and depth of cut was
examined on residual stress in the facing process by
Arunachalam et al. [12]. It was found that increasing depth
of cut leads to high tensile residual stresses at the different
distances from periphery. In addition, cutting tool with
square shape was so prone to generate compressive residual stresses, while machining with round insert generated
tensile residual stresses. Findings of Sharman et al. showed
that machining with feed rate of 0.15 mm/rev resulted in
lower tensile surface residual stresses than machining with
feed rate of 0.25 mm/rev [13]. They also concluded that
tool wear has a signicant effect on tensile residual stresses of the machined surface. The effect of dry and wet
machining was investigated by Devillez et al. It was found
that machining under coolant conditions has a positive
effect on reducing tensile residual stresses, especially at
the low cutting speed (40 m/min) [14]. Outeiro et al. studied the effect of coated and uncoated tool on surface and
subsurface residual stresses [15]. Their ndings showed
that more tensile surface residual stresses were produced
by using uncoated tool, while thickness of tensile residual
stresses were lower when the coated tool was used.
As mentioned at the above paragraph, not only the
effect of machining parameters has not been extensively
investigated on residual stresses, but also different results
have been reported at the previous works. It can be said
that state of residual stress in machining of Inconel718 is
changed signicantly at the different machining conditions. In addition, unfortunately there is not any comprehensive study to evaluate the effect of machining
parameters of this alloy on residual stress state and

optimize the process. Therefore, the aim of the present

study is to evaluate surface residual stress in the nish/
semi-nish turning of Inconel718 superalloy. At rst,
machining residual stress (at the various testing conditions) was measured by X-ray Diffraction (XRD) method.
Then, the process was modeled by Articial Neural
Network (ANN) to estimate the effect of machining
parameters widely on residual stress. At the end, the
optimal machining parameters were accessed by using
ANN and Genetic Algorithm (GA) to obtain minimum
tensile residual stress.
2. Residual stress measurement using X-ray diffraction
method
Residual stresses of manufactured parts can be measured by different destructive and nondestructive methods. X-ray Diffraction (XRD) technique is one of the most
accurate nondestructive methods used for measuring
supercial residual stresses of crystalline materials [16].
Hence, machining residual stresses are measured mainly
by X-ray diffraction method. The basic of this method is
according to the Braggs law illustrated in the following
equation [17]:

nk 2d sinh

where d is distance between atomic planes (d-spacing), k is

wavelength of the incident beam, h is diffraction angle (the
angle between incident/diffracted beam and sample surface) and n is order of diffraction. According to the Braggs
law, diffraction occurs in a specic 2h angle (the angle
between incident and diffracted beam) and d-spacing of
crystal planes can be measured in the given wavelength
of X-ray source.
Since produced residual stress in crystalline materials
leads to change in interplanar spacing, it can be accessed
indirectly by measuring d-spacing. Sin2 w technique is the
most popular technique used for measuring residual stress
by X-ray diffraction method [18]. In this technique, diffraction peak is determined at the high range of 2h angles.
Then, the XRD system is adjusted in this angle and d-spacing of crystal planes is measured in different positions. In
fact, the workpiece is tilted at the different w angles and
d-spacing is measured in each rotation. At the end, residual
stress can be calculated after mathematical simplications
[17,18]. Fig. 1 shows a schematic view of residual stress
measurement by XRD method.
Simplied equations in order to calculate residual stress
by X-ray diffraction method is illustrated in the following
[18]:



dw  d0
2
d0
1 v sin w


E
m
r
1v

2
3

where r is residual stress, E is Youngs modulus, v is Poissons ratio, dn is d-spacing of stress-free crystal planes, dw
is d-spacing of stressed crystal planes in the w direction.
Also, m is slope of tted line in dw versus Sin2 w plot.

F. Jafarian et al. / Measurement 63 (2015) 110

Table 2
Levels of machining parameters for experimental tests.
Machining parameters

Level 1

Level 2

Level 3

Level 4

Cutting speed (m/min)

Feed rate (mm/rev)
Depth of cut (mm)

60
0.015
0.15

80
0.025
0.30

100
0.035
0.45

120
0.045
0.60

conditions are conducted experimentally, the testing conditions were selected based on the Taguchi method. This
method uses desired subset from all of the testing conditions to reduce number of required testing conditions.
Therefore, in this study L32 orthogonal array in Taguchi
method was considered for performing machining tests.
In order to avoid undesirable errors in machining tests,
some preparations were performed. Before conducting
machining tests, to remove out of roundness produced
due to the previous operations, a thin layer from each sample was machined. A laser touch probe was used for each
test to touch the tool nose accurately. Since it has been
shown that tool wear affects machining residual stresses
[13], the machining tests were conducted using fresh tools.
In addition, it was found that the use of cutting uid
resulted in lower tensile residual stress in machining of
Inconel718. [14]. Therefore, all of the samples were
machined under wet conditions. Fig. 2 shows turning process of an Inconel718 sample in wet conditions.
Fig. 1. Schematic view of residual stress measurement using XRD
method: w is tilt angle and h is diffraction angle.

3.3. X-ray analyze and residual stress measurement

The residual stress measurement was carried out by
using Philips X-ray diffractometer (Panalytical Xpert
Pro model). Cr Ka material was selected for X-ray radiation and XRD system was calibrated by stress-free sample.
A phase analyze was carried out on machined and
unmachined sample and diffraction angle was obtained
at 128 and 131, respectively. According to the Braggs
law, generated strain in crystal planes of the machined
sample (change in d-spacing) is a reason for the difference
between diffracted angles. Performed phase analyze is
given in Fig. 3.
After setting the XRD system in the 128 2h, the residual
stress was measured using Sin2 w technique. For this purpose, slope of tted line in d-spacing versus Sin2 w plot
was obtained using PC-Stress software (version 2.61).
Value of Poissons ratio and Youngs modulus were dened
0.29 and 208 (GPa), respectively, and then the residual
stress was calculated by the software. Fig. 4 shows accommodated sample in the XRD system in order to measure
residual stress. Finally, experimental results of the residual
stress with corresponding input parameters were reported
in Table 3. In the rest of the paper, these results were
applied to the intelligent systems in order to estimate
and optimize the process.

3. Experimental procedure
3.1. Workpiece material
At rst, number of required samples was determined
based on the design of experiment. Then, the machining
samples were prepared in 40 mm diameter and 60 mm
thickness to be accommodated in XRD stress analyzer.
Also, all of them were solution annealed at 950 C and were
age hardened at 720 C to nominal bulk hardness of 47
HRC. The chemical composition of the used Inconel718
alloy is shown in Table 1.
3.2. Machining
Finish/semi-nish turning process of Inconel718 was
performed on a rigid CNC lathe using cemented carbide
inserts (DNMG150608). The inserts were mounted on a
Sandvik tool-holder (DDJNL2525M15). The effect of
machining parameters including cutting speed, feed rate
and, depth of cut were investigated in four levels. Table 2
shows range of machining parameters investigated in this
work. Since it is so difcult all of the possible testing

Table 1
The chemical composition of used Inconel718 alloy in wt%.
Ni

Cr

Fe

Nb

Mo

Ti

Al

Si

53.597

17.937

19.047

5.073

2.727

1.87

0.459

0.053

0.019

F. Jafarian et al. / Measurement 63 (2015) 110

Fig. 2. Turning operation of an Inconel718 sample under wet conditions.

Fig. 4. Used XRD system for measuring machining residual stress.

4. Articial intelligent
Predictive and optimization methods are one of the
important branches of articial intelligent utilized widely
in several elds such as mechanical engineering. These
methods can be used as efcient tools in the machining
processes [19]. As an example, Articial Neural Networks
(ANNs) are one the most famous predictive models used
for estimating output(s) of the machining processes
[20,21]. Besides, optimization algorithms (such as Genetic
Algorithm (GA)) as another branch of intelligent methods
are utilized to nd optimal machining conditions [22
24]. Hence, aforementioned tools were used in this paper
so as to estimate and optimize tensile residual stress in
the turning process of Inconel718. In the following subsections, after brief explanation of some basic intelligent
methods, they were used by using some programs written
in MATLAB software.
4.1. Training neural network by GA
Often, traditional methods based on analytical and
mathematical methods have been utilized for training the
neural networks by researchers. Back propagation and gradient descent methods are one of the most conventional

methods of network training [25]. Although mentioned

methods lead to satisfactory results, the problem arises
when these methods are employed for training the neural
networks using few training data. In this condition, capability of the network may be decreased to estimate future
data (increasing testing error). To solve this problem, some
of researchers trained the neural networks by genetic algorithm [26]. Although implementation of the mentioned
method is time-consuming, this method usually leads to
increase in accuracy and performance of the neural network. In this method of training, a multilayer perception
neural network is considered as an initial neural network
topology and weights and biases of the network are considered as optimization variables of GA. Also, Mean Square
Error (MSE) between predicted and actual outputs is
dened as a GA objective function. As a result, in each iteration weights and biases of the neural network are updated
so that MSE of training is reduced. The owchart of ANN
training using GA is shown in Fig. 5.
During network training, up to limited number of
iterations, both testing and training errors are decreased
gradually. But depends on the network capacity, after more
increase in iterations the testing error is not decreased. In
this stage, it is called that the network has been over

Fig. 3. X-ray phase analysis of unmachined and machined Inconel718 sample.

F. Jafarian et al. / Measurement 63 (2015) 110

Table 3
Experimental results at the different machining parameters.
Test
number

Feed rate
(mm/rev)

Depth of
cut (mm)

Cutting
speed
(m/min)

Residual
stress
(MPa s)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32

0.015
0.025
0.035
0.045
0.015
0.025
0.035
0.045
0.025
0.015
0.045
0.035
0.025
0.015
0.045
0.035
0.045
0.035
0.025
0.015
0.045
0.035
0.025
0.015
0.035
0.045
0.015
0.025
0.035
0.045
0.015
0.025

0.15
0.30
0.45
0.60
0.15
0.30
0.45
0.60
0.15
0.30
0.45
0.60
0.15
0.30
0.45
0.60
0.15
0.30
0.45
0.60
0.15
0.30
0.45
0.60
0.15
0.30
0.45
0.60
0.15
0.30
0.45
0.60

60
60
60
60
80
80
80
80
100
100
100
100
120
120
120
120
60
60
60
60
80
80
80
80
100
100
100
100
120
120
120
120

152.8
81.00
195.9
182.3
243.0
522.6
513.9
568.2
230.0
549.7
176.6
192.6
202.6
216.4
210.5
197.4
188.2
175.1
210.4
221.4
185.9
206.2
162.1
196.0
141.7
167.0
197.8
230.8
141.9
179.2
214.9
217.4

Fig. 5. Training of neural network by genetic algorithm.

trained (in other words it over ts the training data) which

leads to increase in testing error and decrease in network
performance. Using GA for ANN training, it is possible to
obtain the most suitable number of iterations to prevent
over tting (over training) of the neural networks. It can
be done by controlling testing error in different iterations
of GA.
5. Results and discussion
In this section, the results of experimental tests were
applied to the intelligent methods in order to estimate
and optimize surface residual stress in the turning process
of Inconel718. At rst, the residual stress was estimated in
the various machining conditions by an ANN model. Then,
to obtain minimum tensile residual stress, the optimal
machining parameters were accessed by genetic algorithm.
5.1. Development of the ANN model
Owing to the fact that conducting several experimental
tests in the manufacturing processes is so difcult, there is
a limitation for number of data set used in the predictive
models. Therefore, implementing a suitable technique for
training articial neural networks plays an important role
in order to increase performance and efciency of the used
method. Authors of the paper at their previous works were
developed an efcient technique for using articial neural
networks in the machining process [2628]. It was shown
that, an implemented technique was used properly for
estimating outputs of the turning process in spite of few
training data. It was based on the combination of Leave
One Out Cross Validation (LOOCV) method and training
the ANNs by genetic algorithm [27]. This technique was
utilized for estimation of residual stress in the present
study.
Because of the above mentioned reasons, the best structure of ANN was accessed using (LOOCV) method. For this
purpose, 31 data from data samples of Table 3 were
selected as training data and a remained data was dened
as a testing data. Then, the neural network was trained
using GA. This operation was repeated 31 times and each
time a new data was selected as a testing data, while training process was performed on the other 31 data samples.
At the end, the mean absolute error of the 32 testing data
was considered as a network error. This method was
implemented on the different structures to choose the
most suitable network topology. It was a multi layer perception neural network with two hidden layers (6 neurons
in the rst layer and 4 neurons in the second layer) and
transfer functions of tansig, logsig, and logsig in the rst
hidden layer, second hidden layer, and output layer,
respectively. Some of the GA parameters include population size of 135, elite count of 8, iteration of 100, migration
Fraction of 0.7 and Migration Interval of 6. Fig. 6 shows the
owchart of the implemented method.
After determining the suitable structure of the neural
network, it should be trained exactly. For this propose,
GA was employed for training the selected network. Number of 27 and 5 data from data samples of Table 3 was

F. Jafarian et al. / Measurement 63 (2015) 110

Fig. 7. Convergence curve of genetic algorithm for training the neural

network.

Fig. 6. Implemented owchart for selecting suitable network structure.

considered as training data testing data, respectively. In

addition, the outputs were normalized to obtain better
performance. Owing to the fact that over training (over
learning) is one of the problems of network training, each
neural network dependent on its learning capacity should
be trained till specic step. Hence, using trial and error
procedure and changing the iterations of GA, the neural
network was trained suitably. The nal errors were
reported in Table 4. Fig. 7 shows convergence diagram of
GA for training the network. In addition, comparison
between predicted values of the neural network (in training and testing data) with corresponding actual values is
given in Fig. 8. As can be seen, not only testing and training
error of the network is low, but also they are near to each
other. It shows the network has been trained adequately.
5.2. Estimation of residual stress state by ANN
As described in the previous sections, the effect of
machining parameters has been investigated slightly on
the residual stress state in machining of Inconel718. Also,
different results have been reported in the previous works.
The reason is attributed to the residual stress sources in
the turning process which are inuenced signicantly by

machining parameters. Therefore, more in depth investigations are needed on this issue. To solve this deciency, we
employed the ANN approach in this study to evaluate
widely the effect of machining parameters (including
cutting speed, feed rate, and depth of cut) on residual
stress in the turning process of Inconel718. In this regard,
in order to cover most of the possible machining conditions, in each time one of the machining parameters was
maintained constant and the effect of the other parameters
were investigated. The obtained results were reported as
follows:
At rst, depth of cut was maintained constant in different levels (0.3, 0.45 and 0.6 mm) and the effect of feed rate
(from 0.015 to 0.045 mm/rev) and cutting speed (from 60
to 120 m/min) were evaluated on the machining residual
stress. The results showed that, increasing cutting speed
from 80 to 110 m/min has a remarkable effect on generating tensile residual stress on the machined surface. It was
also found that range of maximum residual stress (400
550 MPa) shifted from low feed rates to the higher ones
when depth of cut increased. The effect of cutting speed
and feed rate on the machining residual stress (in the
different levels of depth of cut) is shown in Fig. 9.
In the next stage, feed rate was xed in the different
levels (0.015, 0.025, 0.035 mm/rev) and the effect of depth
of cut (from 0.15 to 0.6 mm) and cutting speed (from 60 to
120 m/min) were evaluated on the residual stress. It was
found that increasing cutting speed (from 80 m/min) leads
to producing high tensile residual stresses. Also, the range
of maximum residual stress shifted from low depths of cut
to the higher ones when feed rate increased. Fig. 10 shows
the effect of cutting speed and depth of cut on residual
stress in the different states of feed rate.
At the end, cutting speed was maintained constant (in
the 60, 80 and 100 m/min) and different results were

Table 4
Final errors of the ANN trained by GA (for normalized data between 0 and 1).
MSE of training (using normalized data)

Mean training error

Absolute value of testing error

Mean testing error

0.00285

0.045%

0.08% 0.07% 0.03% 0.02% 0.05%

0.053%

F. Jafarian et al. / Measurement 63 (2015) 110

Fig. 8. Comparison between predicted results of neural network and actual values.

Fig. 9. Effect of cutting speed (Vc) and feed rate (af) on residual stress in the depths of cut (a) 0.3, (b) 0.45 and (c) 0.6 mm.

observed when feed rate and depth of cut were changed

similar to the previous ranges. Low tensile residual stresses
were reported in the whole range of depth of cut and feed
rate when the cutting speed was 60 m/min. In addition, the
minimum range of residual stress (less than 100 MPa)
obtained in the depth of cut between 0.2 and 0.4 mm and
feed rate of 0.015 to 0.03 mm/rev. It was also observed that
in the higher cutting speeds, high tensile residual stresses
produced when both depth of cut and feed rate increased.
Fig. 11 shows the effect of depth of cut and feed rate on the
machining residual stress in the different states of cutting
speed.

5.3. Optimization of the process

In this section, optimal machining parameters were
accessed for minimizing tensile residual stress in the turning process of Inconel718. To do this, the function implemented by the ANN in the previous section was
considered as an objective function of GA, and also
machining parameters were considered as GA variables.
In fact, in each GA generation the machining parameters
were updated so that the residual stress (objective function) was reduced. Finally, the optimal machining parameters were obtained by continuing the optimization

F. Jafarian et al. / Measurement 63 (2015) 110

Fig. 10. Effect of cutting speed (Vc) and depths of cut (ap) on induced residual stress at the feed rate (a) 0.015, (b) 0.025 and (c) 0.035 mm/rev.

Fig. 11. Effect of feed rate (af) and depths of cut (Vc) on induced residual stress at the cutting speed (a) 60, (b) 80 and (c) 100 m/min.

F. Jafarian et al. / Measurement 63 (2015) 110

size of 400, elite count of 3, iteration of 200, migration

Fraction of 0.8, and Migration Interval of 3. Fig. 13 shows
the minimum tensile residual stress and optimal machining parameters predicted by GA.
As can be seen, GA optimal result (44.0256 MPa) is less
than minimum experimental data reported in Table 2
(81 MPa s). In addition, comparison between experimental
and predicted data showed that suggested optimal parameters using GA and range of optimal parameters estimated
by ANN (60 m/min cutting speed, 0.0150.03 mm/rev feed
rate and 0.20.4 mm depth of cut) are in good agreement
with the experimental ndings. Therefore, it can be concluded that, implemented intelligent techniques in this
study have been used excellently for estimation and optimization of surface residual stress in the turning process
of Inconel718.

6. Conclusion

Fig. 12. Employed owchart for optimization of the process.

procedure. The owchart of the employed procedure is

given in Fig. 12.
After
implementing
optimization
procedure,
44.0256 (MPa) was reported as an optimal value of residual stress in the cutting speed of 60 m/min, depth of cut
of 0.249 mm and feed rate of 0.15 mm/rev. Some of the
GA parameters used for this purpose include population

Generally, after machining of Inconel718 alloy tensile

residual stresses are induced on the machined surface.
These stresses are very detrimental for service quality
and component life and they should be removed or minimized during the process. It should be noted that, the
residual stresses are strongly affected by cutting conditions. Unfortunately there is not any comprehensive study
in literature to extensively evaluate the effect of machining
parameters of this alloy on residual stress state and optimize the process. Therefore, the aim of the present study
was to develop a robust approach in order to estimate
and optimize surface residual stress in the nish/semi-nish turning process of Inconel718. For this purpose, after
preparing the samples for stress analysis, they were
machined in the different cutting speed, feed rate and
depth of cut. Then, induced residual stress on the
machined samples was measured by X-ray Diffraction
(XRD) method. After that, obtained results were applied
to the intelligent systems.

Fig. 13. Obtained results of genetic algorithm: (a) minimum residual stress, (b) optimal input parameters.

10

F. Jafarian et al. / Measurement 63 (2015) 110

The ANN approach was used as a predictive model. To

increase performance of the used approach, desired structure of neural network was accessed by LOOCV method.
Then, the selected network was trained by genetic algorithm (GA). After that, the neural network model was used
for estimation of residual stress in the various machining
conditions. In this regard, in each time one of the machining parameters was maintained constant (in the different
levels) and the effect of other parameters were evaluated
on residual stress. The obtained results were reported
and discussed widely in the previous sections.
The trained network was dened as an objective function of genetic algorithm and the optimal residual stress
(44.0256 MPa) was accessed less than smallest experimental data. In fact, implemented intelligent technique in this
work led to discovering results which did not exist in the
experimental data. Also, it was found that estimated optimal parameters and corresponding values of residual
stress were at the same range of experimental data. To
conrm this issue, one experiment was carried out according to the optimal machining parameters obtained by GA.
Finally, a reasonable agreement between new performed
experiment and GA result was observed (44.0256 MPa versus 53.62 MPa). Therefore it can be concluded that implemented intelligent techniques in this paper provide the
robust framework for residual stress estimation in the
turning process of Inconel718. Thus, this method can be
applied to other manufacturing processes as well. More
in detail, the neural network model trained by optimization algorithm can be efciently used to dene an output
function for each manufacturing process even with low
number of experiments. Then, using the GA and function(s)
extracted by neural network, it is possible to nd the optimal process conditions did not obtained by experiments.
Acknowledgments
The present study was supported by Birjand University.
The authors of the paper would like to appreciate
Mr. Saffari and Mr. Banooie for their help to conduct the
experiments.
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