Surface roughness prediction applying artificial neural network at micro machining

Abstract

Micro machining forms an integral part of modern manufacturing technology. In order to satisfy the most important demands, like cost reduction, quality improvement, and production efficiency, this process has to be implemented into the framework of Industry 4.0, too. Defect reduction of products can be realized by beneficial trends of Industry 4.0, such as application of sensors driven AI based predictive models. Surface roughness is one of the main indicators, which can be used for evaluation of the machined surface. The aim of this research is to develop a predictive surface roughness model in the case of micro milling of hard materials. Most important scientific knowledge related to micro milling, and application possibilities of AI based predictive models in the case of chip removal processes were summarised. Micro milling experiments on hot work tool steel (AISI H13) were carried out in order to determine the effect of different cutting parameters on surface roughness. The effects of the cutting parameters were investigated by the analysis of variance (ANOVA). Two-layer feedforward artificial neural network (ANN) based model was trained, validated and tested by means of experimental results. It was found that the trained model has an average MSE, RMSE and R values of 0.00063850, 0.019116835 and 0.9948, while the additional validation test provided 0.00038148, 0.019531513 and 0.8545, respectively, which are statistically significant. The developed model can effectively predict the surface roughness under the investigated circumstances.