Precision Face Milling of Maraging Steel 350: An Experimental Investigation and Optimization Using Different Machine Learning Techniques

Abstract

Maraging steel, characterized by its superior strength-to-weight ratio, wear resistance, and pressure tolerance, is a material of choice in critical applications, including aerospace and automotive components. However, the machining of this material presents significant challenges due to its inherent properties. This study comprehensively examines the impacts of face milling variables on maraging steel’s surface quality, cutting temperature, energy consumption, and material removal rate (MRR). An experimental analysis was conducted, and the gathered data were utilized for training and testing five machine learning (ML) models: support vector machine (SVM), K-nearest neighbor (KNN), artificial neural network (ANN), random forest, and XGBoost. Each model aimed to predict the outcomes of different machining parameters efficiently. XGBoost emerged as the most effective, delivering an impressive 98% prediction accuracy across small datasets. The study extended into applying a genetic algorithm (GA) for optimizing XGBoost’s hyperparameters, further enhancing the model’s predictive accuracy. The GA was instrumental in multi-objective optimization, considering various responses, including surface roughness and energy consumption. The optimization process evaluated different weighting methods, including equal weights and weights derived from the analytic hierarchy process (AHP) based on expert insights. The findings indicate that the refined XGBoost model, augmented by GA-optimized hyperparameters, provides highly accurate predictions for machining parameters. This outcome holds significant implications for industries engaged in the machining of maraging steel, offering a pathway to optimized operational efficiency, reduced costs, and enhanced product quality amid the material’s machining challenges.