A COMPARATIVE MODELING AND OPTIMIZATION OF SURFACE ROUGHNESS IN THE END MILLING OF Al 3003 SUBJECTED TO NON-EQUAL CHANNEL ANGULAR PRESSING (NECAP)

Abstract

This paper highlights the surface roughness optimization of a specific material, Al 3003, which has been subjected to the non-equal channel angular pressing (NECAP) process. Considering spindle speed, feed rate, and depth of cut as input variables and surface roughness as an output variable, experiments have been conducted based on the L27 orthogonal array of the Taguchi method. Four prediction models, namely exponential and response surface methodology (RSM) as mathematical models, and artificial neural networks (ANNs) prediction models with different training algorithms (Bayesian Regularization (BR) and Levenberg–Marquardt (LM)), are proposed. Applying effectiveness and performance criteria, the prediction accuracy of the exponential model (90.35%), RSM (93.07%), BR (97.83%), and LM (97.54%) shows that all proposed prediction models are efficient enough. The ANN model trained with BR is found to be the best fit for predicting surface roughness. In order to optimize surface roughness, a newly introduced optimization method called the Intelligible-in-time Logics Algorithm (ILA) is employed. High spindle speed (1000[Formula: see text]rev/min), low feed rate (100[Formula: see text]mm/min) and depth of cut (0.5[Formula: see text]mm) have been the optimum cutting parameter combinations to obtain minimum surface roughness (0.4956[Formula: see text][Formula: see text]m). The results have been verified by confirmation tests and Particle Swarm Optimization (PSO) method. ILA and PSO predict the same optimum parameter combinations and minimum surface roughness, while ILA performs optimization in less time (114.4[Formula: see text]s), about 3.5 times faster than PSO. The paper’s findings strongly advocate the application of ILA in machining data optimization.