Multi-attribute optimization of eco-manufacturing based criteria in CNC manufacturing systems using an evolutionary algorithm

Abstract

Manufacturing technology has evolved over the years with the development of CNC manufacturing systems, flexible manufacturing, rapid prototyping, smart manufacturing etc Simultaneously, the development of new and exotic materials to match specific requirements has shaped new problems in manufacturing. The materials developed thus far require special tools, lubricating agents, and extra-care in machining without compromising the quality. Further the study of carbon emissions in manufacturing sector has also gained unusual spotlight in view of their deleterious effect on the ecological balance. The manufacturing systems have to be consequently designed and developed, such that they generate minimal quantity of emissions without forfeiting the prime objectives of quality and tool morphology. The present work is principally intended to analyse the effect of cutting parameters on the emission rate of greenhouse gases, tool wear and work-piece temperature concurrently. These studies are accomplished in both dry and wet conditions on computer numerical control machining system. The machining process involved plain facing of a Ti-6Al-4V hardened material. The experimental studies are realized using both single point and multi-point cutting tools and are supplemented with the application of Multi-Objective Genetic Algorithm (MOGA). The MOGA generated set of pareto-fronts for the four machining conditions were subjected to VIKOR, TOPSIS and LINMAP decision making approaches to arrive at the optimum values of decision variables. The optimum cutting parameters obtained in single point cutting tool machining in dry conditions are speed (873.2 rpm), feed (0.199 mm rev−1) and depth of cut (0.25 mm), while the corresponding values of responses are tool wear (67.19 μm), work-piece temperature (39.36 °C) and carbon emission (0.138 Kg-CO2). The equivalent values for multi-point cutting were determined as 899.8 rpm, 0.195 mm rev−1 and 0.25 mm, while the responses for these optimal conditions are 69.92 μm, 39.48 °C and 0.137 Kg-CO2 in that order.