The study focuses on improving the production processes' dimensional accuracy for thick materials through the optimization of the area of contact during machining, forming, and additive manufacturing. The performance and dependability of components depend heavily on dimensional accuracy, especially in sectors like heavy machinery, automotive, and aerospace, which demand high precision. The research employs predictive modeling using machine learning algorithms and optimization techniques to determine the optimal contact area that minimizes deviations in final dimensions. The process parameters were modeled, predicted, and enhanced by the use of Response Surface Methodology (RSM) and Artificial Neural Networks (ANN). To design experiments, the central composite design is applied with machining trials conducted on a CNC machine. The results show that optimizing the contact area significantly improves stress distribution, reduces deformation risks, and enhances overall dimensional accuracy. Key findings include the validation of a quadratic model for predicting the area of contact, which demonstrated high statistical significance and predictive accuracy. The ANN model further corroborated these results, showing strong correlation and minimal error in predictions. The study offers a strong framework that producers can use to process thick materials more precisely and effectively by leveraging advanced modeling and optimization techniques.
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