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IN THE NAME OF ALLAH SWT THE

MOST BENEFICIAL, THE MOST
MERFICUL
5/16/2019
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5/16/2019

OPTIMIZATION OF SURFACE ROUGHNESS Ra USING RESPONSE

SURFACE METHADOLOGY and GA
Semester Project Presentation

INSTRUCTOR
Dr. Salman

GROUP MEMEBERS
Muhammad Waqas Hanif 18-MSc-IED/FT-01
Anib Ul Ghani Butt 17-Msc-IE/EM-PT-19

Department of Industrial Engineering

University of Engineering and Technology
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Table of contents
• Introduction
• Problem Statement
• Literature Review
• Response Surface Methodology
• Analysis
• Limitations and Recommendations
• Results & Conclusions
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Introduction
• A finishing process at which material is first thermally treated to
achieve certain hardness and afterward machined to get the required
shape is called Hard Facing machining operation
• Benefits of Hard facing
▫ low overall processing time
▫ elimination of intermediate process
▫ substantial reduction of manufacturing costs
▫ decrease of production time
▫ achievement of comparable surface finish
▫ reduction or elimination of environmentally harmful cooling media
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Introduction
• Steps required to hard face turning process
• At 1st step :Heat treated in electrical arc furnace at 800 degree
centigrade and quenched in oil.
• At 2nd step : perform an experiment as per design of experiments

Final hard face After experiments

Heat treated
shape shape
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PROBLEM STATEMENT
• It is now fighting to supplant the grinding process because it
consists of machining parts having hardness value in range of
45–70 HRC, it is evident that the challenge of cutting tool and
cutting conditions selection is often present. For this purpose,
numerous researches have been conducted using different
computational methods in modeling and optimization. The
optimization problem is mathematically defined as the
research of the optimum (minimum or maximum) for a given
function (i.e surface roughness).
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Methodology
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PHASE
01
Literature review Material selection

Model development

PHASE
model

02
validation?

Compare with Algorithm

PHASE
Results &
conclusion

03
end
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RESPONSE SURFACE METHODOLOGY

• Mathematical and Statistical
• Optimization of Response Value
• Experiment / Run
• Design of Experiment
• Evaluation of Response
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GENETIC ALGORITHM 5/16/2019

• Optimization technique
• Population-random solutions
• Evaluation based on fitness function
• Selection Method
• Tournament Selection
• Roulette Wheel Selection
• Crossover
• One point
• Two point
• Uniform
• Mutation
• Termination
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Proposed Methodology
• RSM is used to predict the surface roughness in Hard face turning operation for
known values of depth of cut, cutting speed and feed rate.
• The ANOVA is performed using Design Expert 7.0 software and then the process
parameters are optimized using genetic algorithm GA to obtain minimum surface
roughness (Ra).

Material Carbon alloy

Diameter 44 mm

Machine used CNC lathe machine

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Literature review
Sr. Title (year 2018) Methodology Adopted
Technique/
Major Findings
Conclusions and
Algorithm used Future Work

Modeling of Surface The mathematical RSM The analysis of variance These models can
Roughness Using model is developed revealed that the material be used in
RSM, FL and SA in by using response Fuzzy hardness exerts the most industries to
Dry Hard Turning surface inference dominant effect effectively control
methodology system (FIS) the hard turning
(RSM), predictive process to achieve
model is made by Simulated a good surface
1. using fuzzy annealing (SA) quality.
inference technique
system (FIS), and
optimization model
is formulate by
using simulated
annealing (SA)
technique
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Literature review 5/16/2019

Sr No. Title
Methodology Technique/
Major Findings
Conclusions and
Adopted Algorithm used Future Work

Effects of cryogenic Central composite RSM cryogenic cooling modifying the the optimum flow
cooling on the surface design is used to work piece surface integrity, rate and pressure of
design an
integrity in hard turning providing low values of surface liquid nitrogen for
experiment and
of AISI D6 steel. optimize by using roughness as well as higher values different cutting
2
(2018) RSM of surface micro hardness. condition sand
work piece material
is still unclear

Prediction of surface The effects of Artificial Neural Machining with larger nose radius Studying the tool
roughness and cutting the process Networks (ANN) and lower feed wear and the tool
forces using RSM, ANN, inputs are technique. rate produces surfaces with better vibration effects on
and NSGA-II in finish evaluated by functional characteristics. the output responses
turning of AISI 4140 using RSM. NSGA-II is more efficient of the hard
hardened steel with Optimize the than DF method turning process
Mixed ceramic tool. parameters by By using these
3
(2018) using the technique .
sorting Genetic
Algorithm
(NSGA-II)
coupled
with ANN
models
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RESPONSE SURFACE DESIGN

• There are two main types of response surface designs:
• Central Composite designs
Central Composite designs can fit a full quadratic model. They are often
used when the design plan calls for sequential experimentation because
these designs can include information from a correctly planned factorial
experiment.
• Box-Behnken designs
Box-Behnken designs usually have fewer design points than central
composite designs, thus, they are less expensive to run with the same
number of factors.
Box-Behnken designs always have 3 levels per factor, unlike central
composite designs which can have up to 5.
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Factor Level for the Parameters: 5/16/2019

Parameters Selection:
Factors Levels

-1 0 1

Cutting speed 60 100 140

(m/min)
Depth of cut (mm) 0.25 0.50 0.75

Feed rate (mm/r) 0.05 0.10 0.15

Optimized Parameters MINIMUM

Feed rate Cutting Speed Depth of cut Obs. response VALUE OF
(mm/rev) (m/min) (mm) THE
RESPONSE AT
PARAMETERS
.05 140 0.75 0.146
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Experimental Design Matrix 5/16/2019

Observed
Responses

MINIMUM VALUE OF THE

RESPONSE AT
PARAMETERS
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DESIGN SUMMARY

Responses
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ANNOVA 5/16/2019
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REGRESSION EQUATION & P vs A Graph 5/16/2019

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CONTOUR GRAPHS 5/16/2019

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3D Plots of cutting speed and other

parameters for Surface Roughness
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Analysis & Results

• ANOVA is performed to confirm the adequacy of the model. The F

ratio of the model is less than the standard value and Hence the
model is adequate at 95% confidence interval.
• For the current application the best minimum roughness value is
attained at 300th iteration with the above mentioned parametric
values.
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Genetic Algorithm 5/16/2019

Fitness
Function

Steps:
• Create m-file.
• Run the Code.
• Enter Optimal-tool on Command Window.
• Define the lower and upper bounds of the parameters.
• Run the Tool to obtain Results and Graphs.
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Genetic Algorithm response 5/16/2019

Optimized Results
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Graphical Demonstrations
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Results & COMPARISON

DESIGN OF EXPERIMENTS RESULTS GENETIC ALGORITHM RESULTS
Optimized values at experiment no 19 out of Optimized values at iteration no . 102
20 experiments

No of variables 03 No of variables 03
Parameters Parameters
Speed=140 Speed=115.25
Feed=0.05 Feed=0.05
Depth of cut = 0.75 Depth of cut = 0.443

Response=0.146 Response=0.1169
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Limitations & Recommendations

• Limitations
▫ Experimental Setup
▫ Material availability
• Recommendations
▫ Empirical modelling approach
▫ Comparison of optimization methods
▫ HS algorithm
▫ PSO algorithm
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CONCLUSION
• Model: second order mathematical
• Model adequacy check using ANOVA
• Main and interactions are shown using graphs
• Optimization is achieved using GA
• The predicted and observed values are approximately same with a
reliability of 99.69%
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QUESTIONS AND SUGGESTIONS

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REFERENCES
1. Ikhlas Meddour, Mohamed Athmane Yallese, Hamza Bensouilah,Ahmed Khellaf, Mohamed Elbah
(2018) Prediction of surface roughness and cutting forces using RSM, ANN, and NSGA-II in finish
turning of AISI 4140 hardened steel with mixed ceramic tool. International Journal Mechanical
Tools Manufacturing 97:1931–1949
2. Mozammel Mia, Nikhil Ranjan Dhar (2018) Modeling of Surface Roughness Using RSM, FL and SA
in Dry. Arab Journal of Science and Engineering 57:83–101
3. Jawahir IS, Attia H, Biermann D, Duflou J, Klocke F, Meyer D, Newman ST, Pusavec F, Putz M, Rech
J, Schule V, Umbrello D (2018) Cryogenic manufacturing processes. CIRP Ann Manufacturing
Technology 65:713–736
4. Samir Khamel, Nouredine Ouelaa, Khaider Bouacha1 (2012) Analysis and prediction of tool wear,
surface roughness and cutting forces in hard turning with CBN tool. Journal of Mechanical Science
and Technology 11:3605~3616