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Journal of Manufacturing Processes xxx (2014) xxxxxx
Institute for Machine Tools, Stuttgart University, Holzgartenstr.17, D-70174 Stuttgart, Germany
Institute for Materials Testing, Materials Science and Strength of Materials, Stuttgart University, Pfaffenwaldring 32, D-70569 Stuttgart, Germany
a r t i c l e
i n f o
Article history:
Received 14 January 2014
Received in revised form 25 March 2014
Accepted 9 May 2014
Available online xxx
Keywords:
Duplex stainless steels
Response surface methodology
Cuckoo search
TOPSIS
Operational sustainability index
a b s t r a c t
The attractive combination of high mechanical strength, good corrosion resistance and relatively low cost
has contributed to making duplex stainless steels (DSSs) one of the fastest growing groups of stainless
steels. As the importance of DSSs is increasing, practical information about their successful machining
is expected to be crucial. To address this industrial need, standard EN 1.4462 and super EN 1.4410 DSSs
are machined under constant cutting speed multi-pass facing operations. A systematic approach which
employs different modeling and optimization tools under a three phase investigation scheme has been
adopted. In phase I, the effect of design variables such as cutting parameters, cutting uids and axial length
of cuts are investigated using the D-Optimal method. The mathematical models for performance characteristics such as; percentage increase in radial cutting force (%Fr ), effective cutting power (Pe ), maximum
tool ank wear (VBmax ) and chip volume ratio (R) are developed using response surface methodology
(RSM). The adequacy of derived models for each cutting scenario is checked using analysis of variance
(ANOVA). Parametric meta-heuristic optimization using Cuckoo search (CS) algorithm is then performed
to determine the optimum design variable set for each performance. In the phase II, comprehensive
experiment-based production cost and production rate models are developed. To overcome the conict
between the desire of minimizing the production cost and maximizing the production rate, compromise
solutions are suggested using Technique for Order Preference by Similarity to Ideal Solution (TOPSIS).
The alternatives are ranked according to their relative closeness to the ideal solution. In the phase III,
expert systems based on fuzzy rule modeling approach are adopted to derive measures of machining
operational sustainability called operational sustainability index (OSI). Articial neural network (ANN)
based models are developed to study the effect of design variables on computed OSIs. Cuckoo search
neural network systems (CSNNS) are nally utilized to constrainedly optimize the cutting process per
each cutting scenario. The most appropriate cutting setup to ensure successful turning of standard EN
1.4462 and super EN 1.4410 for each scenario is selected in accordance with conditions which give the
maximum OSI.
2014 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.
1. Introduction
Duplex stainless steels (DSSs) are chromiumnickel
molybdenumiron bi-phased alloys in which the proportions
of the constituent elements enable the optimization of the balance
of the volume fractions of austenite and ferrite [1]. In many ways,
the duplex stainless alloys represent a best of both worlds in
combining traits from the austenitic and ferritic alloys. They have
Corresponding author. Tel.: +49 711 685 84558; mobile: +49 163 9187997.
E-mail addresses: rastee.ali@ifw.uni-stuttgart.de (R.D. Koyee),
siegfried.schmauder@imwf.uni-stuttgart.de (S. Schmauder).
1
Tel.: +49 711 685 83860; fax: +49 711 685 73860.
2
Tel.: +49 711 685 83876; fax: +49 711 685 83858.
3
Tel.: +49 711 685 62556; fax: +49 711 685 62635.
http://dx.doi.org/10.1016/j.jmapro.2014.05.004
1526-6125/ 2014 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.
Please cite this article in press as: Koyee RD, et al. Modeling and optimization of turning duplex stainless steels. J Manuf Process (2014),
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of metals with multiple performance characteristics and application of one or more multiple attribute decision making (MADM)
techniques to optimize the process parameters [1218]. Considering the drawbacks of traditional optimization techniques, attempts
are being made to optimize the multi-pass machining problem using evolutionary optimization techniques [1924]. Logical
fuzzy reasoning has been applied to multiple output optimization of machining processes [2527]. As investigated by previous
researchers, the articial neural network (ANN) is a powerful tool
for dealing with the complex nature of the cutting process [2830].
A number of attempts have also been made to study the machining of DSSs experimentally [3135]. For instance, Nomani J. and
his coworkers have conducted machinability tests on duplex alloys
SAF 2205 and SAF 2507, while employing austenite stainless steel
316L as a benchmark during drilling. Both duplex alloys displayed
poorer machinability responses, with 2507 being worst [36]. De
Oliveira et al. studied the turning operation of SAF 2507, and its
inuence on the alloys corrosion resistance in practical applications. The results indicate that turning with PVD-coated inserts
under high-pressure cooling resulted in long tool lives, good workpiece roughness and high corrosion resistance of the material after
machining. The most frequent wear mechanism found during the
tests was notch wear, while the main tool wear mechanism was
attrition [37]. Selvaraj et al. are optimized dry turning parameters
of two different grades of nitrogen alloyed duplex stainless steel by
using Taguchi method. Their results revealed that the feed rate is
the more signicant parameter inuencing the surface roughness
and cutting force. The cutting speed was identied as the more
signicant parameter inuencing the tool wear [38]. Most recent
works of Krolczyk et al., in their fourth contribution, identied
microhardness of surface integrity (SI) after turning with wedges of
coated sintered carbide. The investigation included microhardness
analyses in dry and wet machining of duplex stainless steel. It has
been shown that wet cutting leads to the decrease of SI hardening depth, while increasing the rounded cutting edge radius of the
wedge increases the maximum microhardness values and the hardening depth [39]. Finally, some recently conducted studies have
focused on machining technologies in order to achieve sustainable
development objectives [4044].
In majority of the aforesaid past researches, very few efforts
have been made toward application of recent modeling and optimization techniques for optimizing the machining of DSSs. In order
to provide a scientic approach to select the most proper cutting
condition for machining DSSs, this paper presents the application of
relatively new statistical techniques in experimental design, articial intelligence, MADM and recently developed meta-heuristic
optimization algorithms in the context of a three phase investigation. The owchart of the study is shown in Fig. 1.
D- Optimal design
Categorical factors: Cutting Fluid Type
vc
m/min
mm/rev
Lc
ap
mm
mm
VB
%F r
mm
Pc
W
Fuzzy
Logic
MADM
(TOPSIS)
OSI
Ranking
Preference
Optimum
Cutting set
Lc ap f
vc
Adjust Network
via Taguchi
OSI predict.
No
min(MSE)?
OSI actual.
Yes
Inputs
Neural Network
Model
Outputs
CSNNS
Feasible region C1
Feasible
region C2
Solution
Feasible
region C3
Fe a sible
re gion C4
Optimized
Cutting
Parameters
Fig. 1. Flow chart of the study.
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Table 1
Workpiece materials properties.
Mechanical properties
Yield strength (MPa)
Tensile (MPa)
Hardness (BHN)
Elongation (%)
EN 1.4462
EN 1.4410
0.018
22.42
5.44
3.12
0.84
0.37
0.18
0.025
0.0033
0.015
24.92
6.91
4.06
0.75
0.25
0.3
0.021
0.0007
Fig. 2. Constant cutting speed facing operation.
514
737
212
41
579
826
236
40
Table 2
Process parameters.
Numerical factor levels
Low level
High level
75
0.1
0.5
3
Wet
200
0.25
1.5
12
Dry
Frmax Frinit
(1)
Frinitial
where Frmax . is the maximum and Frinit . is the initial radial cutting
forces in each experimental run. In Fig. 3, a typical radial force signal
of wet cutting EN 1.4462 at vc = 200 m/min, f = 0.25 mm/rev, ap = 1.5,
Lc = 12 mm is shown, indicative of the increasing trend when the
total length of cut has been reached. The average radial cutting
force in constant cutting speed area in every cutting pass per cutting run is calculated and the cutting pass with maximum value is
designated. In order to compute all increasing percentages in the
study, a total of 236 cutting passes per category and 472 cutting
passes per material have to be similarly analyzed.
One of the most important items related to cleaner production consists in reducing energy consumption in order to cut down
carbon emissions associated to energy generation. Therefore, the
association of environmental footprint in view of minimization of
motor power per each experimental run was considered. The power
consumed by the motor of a machine tool is composed of an effective and an idle component. Because of its proportionality to the
torque emitted by the motor, the effective power is often used as
a signal within the control system for quantifying the motor load.
600
500
400
300
200
100
0
10
20
30
40
50
60
70
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3.U.I. cos
(2)
(3)
XTY
(4)
XT ,
transpose of the
where b, matrix of parameter estimates;
independent variables matrix (X); Y, matrix of the performance
characteristic.
2.4. Cuckoo search
Cuckoo Search is one of the latest nature-inspired metaheuristic algorithms, developed by Xin-She Yang and Suash Deb
[48]. Cuckoo Search is inspired by lifestyle of a bird family called
cuckoo. Specic egg laying and breeding of cuckoos is the basis
of this optimization algorithm. Like other evolutionary algorithms,
the proposed algorithm starts with an initial population of cuckoos. These initial cuckoos have some eggs to lay in some host birds
nests. Some of these eggs which are more similar to the host birds
eggs have the opportunity to grow up and become a mature cuckoo.
Other eggs are detected by host birds and are killed. The grown eggs
reveal the suitability of the nests in that area. The more eggs survive in an area, the more prot is gained in that area. So the position
in which more eggs survive will be the term that cuckoo optimization algorithm is going to optimize [49]. For simplicity in describing
Cuckoo Search the following idealized assumptions are made:
a. Each cuckoo lays one egg at a time, and dumps its egg in a randomly chosen nest.
b. The best nest with high-quality eggs will be carried over to the
next generation.
c. The number of available host nests is xed, and the egg laid by
a cuckoo is discovered by the host bird with a probability Pa
between 0 and 1. In this case, the host bird can either get rid
of the egg, or simply abandon the nest and build a completely
new nest.
3. Results and discussions
3.1. Effect of independent cutting variables on performance
characteristics
The values of regression coefcients in natural form and various statistics about the statistical validity of the developed models
2
at a 95% condence interval are given in Table 4. The R2 and Radj
.
values indicate that the models t the data well. As per analysis of
variance (ANOVA) technique, since the calculated value of Fratio of
all developed second-order models are greater than the standard
tabulated value of the table (F14,9,0.05 = 3.03), then the models are
considered adequate within the condence limit. The adequate
precision (Aprec. ) for all models are greater than 4, which indicate
an adequate signal to noise ratio, thus the models can be used to
navigate the design space.
3.1.1. Effect of independent cutting variables on the percentage
increase in radial cutting force (%Fr )
In phase I, the developed RSM models were utilized to study
the interaction effects of selected independent variables on %Fr .
To analyze the interaction effects, three dimensional plots were
generated considering two parameter at a time while the other
parameters are held constant at their respective center levels. These
interaction plots are presented in Fig. 4a. From which, the following
observations can be made:
a. For a given depth and length of cut, %Fr approaches its minimum value as cutting speed and feed rate increase to certain
Please cite this article in press as: Koyee RD, et al. Modeling and optimization of turning duplex stainless steels. J Manuf Process (2014),
http://dx.doi.org/10.1016/j.jmapro.2014.05.004
EN 1.4462
vc (m/min)
f (mm/r)
ap (mm)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
200
75
75
200
200
200
75
137.5
75
200
75
200
200
200
75
75
75
200
200
200
75
137.5
137.5
75
75
137.5
200
106.25
137.5
200
75
200
200
75.0
137.5
200
75
168.75
75
200
200
137.5
200
75
75
75
75
200
0.25
0.25
0.25
0.25
0.25
0.10
0.17
0.17
0.25
0.10
0.10
0.25
0.10
0.10
0.25
0.10
0.25
0.25
0.25
0.25
0.10
0.17
0.17
0.25
0.10
0.10
0.10
0.21
0.10
0.25
0.17
0.17
0.17
0.10
0.25
0.10
0.10
0.14
0.17
0.10
0.25
0.25
0.10
0.25
0.10
0.25
0.10
0.17
1.5
1.5
1.5
0.5
0.5
0.5
1
1.5
1
1.5
1.5
0.5
1.5
0.5
1.5
0.5
0.5
1.5
1
1.5
1.5
1
1
0.5
0.5
1
1.5
0.75
1.5
1.5
1.5
1
1.5
0.5
1.5
0.5
1
0.75
0.5
0.5
0.5
0.5
1
0.5
0.5
0.5
1.5
0.5
Lc (mm)
12
7.5
3
12
3
12
7.5
7.5
3
3
12
12
12
3
12
3
3
3
12
3
3
3
12
3
12
7.5
7.5
7.5
3
3
3
7.5
12
7.5
12
12
12
7.5
12
12
7.5
3
3
12
3
12
12
3
EN 1.4410
Cutting cond.
%Fr
Pe (W)
VBmax (m)
%Fr
Pe (W)
VBmax (m)
Wet
Dry
Wet
Wet
Wet
Wet
Wet
Wet
Dry
Wet
Wet
Wet
Wet
Wet
Wet
Dry
Wet
Dry
Dry
Wet
Wet
Wet
Wet
Wet
Wet
Wet
Dry
Dry
Dry
Dry
Dry
Wet
Dry
Dry
Dry
Dry
Dry
Dry
Dry
Dry
Dry
Dry
Dry
Wet
Wet
Dry
Dry
Dry
21.777
18.382
9.660
26.401
12.545
10.383
15.900
5.609
15.258
11.280
19.086
26.401
16.737
11.791
20.717
20.418
14.300
25.026
36.770
10.733
14.310
2.265
10.520
14.300
25.617
12.708
26.499
15.115
10.559
27.016
10.830
14.471
28.663
21.113
16.158
55.258
32.324
19.217
24.680
55.988
37.156
13.758
24.212
25.459
17.480
29.590
17.597
18.255
4236.490
1815.024
1000.050
3489.350
3234.730
3545.790
923.635
1904.170
958.954
3143.700
968.770
3487.520
3294.360
3155.320
1306.680
912.855
912.033
4556.128
4621.133
4072.790
793.157
1781.650
1616.510
913.133
838.760
1592.840
3634.899
1558.224
1946.809
4556.128
1206.554
3672.370
3330.270
996.490
2718.074
3293.114
1146.716
2197.682
959.551
3313.114
3557.210
2240.772
3207.704
998.866
759.173
1052.569
1051.178
3232.602
193.784
117.880
70.967
211.677
109.044
93.154
101.364
75.312
98.648
93.781
154.679
211.693
131.510
137.022
134.271
130.369
91.209
178.543
230.010
93.302
114.375
59.643
89.178
88.608
146.160
82.713
167.532
97.768
79.498
180.683
71.187
112.962
180.719
234.622
124.200
448.002
203.001
127.007
156.435
446.414
232.355
109.378
152.577
122.391
132.548
216.367
113.056
119.098
32.025
159.015
116.754
105.655
96.068
105.939
99.369
91.591
24.016
59.867
97.277
106.946
63.959
101.368
128.988
88.146
98.674
33.886
17.753
21.022
92.396
50.501
55.124
97.675
74.074
69.125
121.988
69.057
115.750
34.013
139.880
48.026
29.875
111.258
65.049
119.785
104.255
98.879
126.020
121.665
116.846
56.322
64.148
107.104
70.778
119.995
112.556
69.339
30.187
20.390
10.415
32.821
16.319
13.734
15.100
10.485
11.977
14.307
23.861
32.821
19.961
21.276
20.597
24.504
13.590
31.561
41.417
13.953
17.752
8.102
12.997
13.075
22.044
11.703
30.389
19.021
14.382
30.553
13.057
16.727
35.530
26.133
20.386
61.414
11.022
23.357
29.416
61.414
42.082
22.933
26.892
18.372
20.114
34.714
23.056
22.813
4451.450
2222.079
1063.860
3566.580
3467.240
3887.250
1011.250
2018.540
980.695
3356.980
1100.785
3586.330
3489.570
3489.670
1512.830
831.534
998.238
5748.831
5493.925
4189.540
842.735
1884.760
1745.240
985.853
996.367
1606.870
3848.593
1547.884
2052.213
5739.279
1332.649
4016.450
3622.993
1027.255
2812.954
3579.649
1071.263
2201.888
913.944
2934.255
3557.355
1971.538
3514.131
1208.460
845.423
955.323
1075.786
3447.930
186.874
134.668
85.757
225.957
111.492
93.819
137.964
57.276
92.118
98.180
164.205
225.972
145.644
103.697
176.426
160.162
124.067
203.640
284.183
95.447
122.340
29.152
95.351
124.555
218.835
114.160
216.633
126.149
97.116
197.442
88.758
128.364
234.047
170.221
134.641
579.189
81.977
153.066
190.451
586.846
268.086
150.439
185.018
215.834
151.705
205.826
153.231
153.748
37.488
157.925
141.096
115.255
100.109
114.013
105.846
111.865
71.809
66.079
106.946
117.567
76.158
123.895
155.125
91.102
113.855
39.962
29.796
25.092
105.448
75.026
82.567
112.115
81.368
83.558
119.588
86.653
123.736
38.267
147.997
60.467
57.999
155.727
30.174
138.548
122.984
117.180
145.013
139.975
135.383
84.121
91.980
118.025
80.757
128.617
140.951
65.265
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Independent variables
G Model
Exp. No
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Table 3
Experimental results.
G Model
Coef.
EN 1.4462
EN 1.4410
%Fr
VBmax
Pe
%Fr
Pe
VBmax
Dry
Wet
Dry
Wet
Dry
Wet
Dry
Wet
Dry
Wet
Dry
Wet
Dry
Wet
Dry
70.6
0.59
386.
9.22
1.58
0.00
931
6.29
0.10
0.38
0.03
0.00
22.1
5.81
0.02
69.4
0.48
435
0.74
1.70
0.00
1235
1.34
0.08
0.01
0.03
0.01
31.8
5.36
1.64
1700.9
20.63
1384.5
811.25
61.81
0.13
3539.4
88.09
3.74
11.96
1.78
0.08
3421.3
16.90
3.13
2165.7
5.30
23259
0.52
46.41
0.07
50,842
8.97
0.54
36.67
0.23
0.06
3590.9
97.45
36.41
467.2
3.03
1550
69.37
10.37
0.01
2176
27.36
0.08
3.88
0.06
0.01
73.52
48.25
3.56
604.2
1.91
4341.5
257.56
19.05
0.01
11,795
103.39
0.44
0.95
0.16
0.07
580.6
58.30
14.68
29.8
0.67
412.3
144.9
13.30
0.00
95.65
118.20
0.90
2.46
0.65
0.00
117.5
5.89
0.02
88.9
0.32
401.5
173.5
31.54
0.00
737.5
166.96
1.60
1.27
0.65
0.02
93.95
26.88
7.57
75.8
0.51
253.4
10.17
1.94
0.00
358.9
4.15
0.03
0.62
0.01
0.00
12.25
8.00
0.58
22.3
0.21
160.1
21.75
2.01
0.00
425.8
9.63
0.11
0.28
0.04
0.00
35.85
4.00
0.60
1765.7
25.55
5243
1274.9
59.15
0.16
21,964
236.10
2.81
3.69
1.52
0.04
4036.3
9.61
11.06
2013.1
18.75
14,453
1963.4
181.15
0.06
8438.1
869.17
9.98
25.30
3.76
0.42
3235.8
360.96
54.40
576.9
4.70
3123
65.42
13.86
0.01
7473.3
47.89
0.88
3.24
0.28
0.01
176.9
46.71
0.07
176.2
1.64
1265.2
171.8
15.86
0.01
3365
76.09
0.87
2.21
0.33
0.04
283.2
31.60
4.76
16.31
1.56
732.1
143.2
6.91
0.00
666.4
119.06
0.58
3.27
0.74
0.00
77
9.78
0.52
76.65
0.71
550.24
74.7
6.90
0.00
1463.4
33.09
0.38
0.96
0.14
0.02
123.2
13.74
2.07
ANOVA
R2
2
Radj
0.96
0.90
0.97
0.93
0.99
0.98
0.98
0.95
0.92
0.80
0.98
0.95
0.97
0.91
0.93
0.83
0.92
0.80
0.95
0.87
0.99
0.97
0.97
0.93
0.96
0.89
0.97
0.92
0.97
0.93
0.94
0.85
RMSE
Aprec.
Fratio.
Reg. DF
Err. DF
2.09
14.9
15
14
9
18.6
9.82
7.57
14
9
21.4
22.91
32.9
14
9
8.33
15.57
17.8
14
9
16.8
9.66
8.89
14
9
3.01
9.82
7.62
14
9
4.86
12.67
12.4
14
9
212
21.59
61.3
14
9
423
14.67
21.9
14
9
17.4
14.53
14.5
14
9
37
17.33
19.2
14
9
8.27
19.1
21.6
14
9
b0
b1
b2
b3
b4
b11
b22
b33
b44
b12
b13
b14
b23
b24
b34
3.2
17.7
22.3
14
9
179
24.5
79.9
14
9
274
17.1
34.8
14
9
RMSE, root mean squared error; Reg. DF, regression degrees of freedom; Err. DF, error degrees of freedom.
16.1
9.465
10.6
14
9
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Table 4
Models coefcients estimates and ANOVA.
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Fig. 4b illustrates the interaction effects of the independent variables on the effective cutting power. It is seen from this collective
gure that:
a. Effective cutting power is most sensitive to cutting speed variations when other parameters are kept constant. Maximum and
minimum consumptions in effective cutting power are seen at
wet cutting of EN 1.4462 and dry cutting of EN 1.4410 respectively.
b. Effective cutting power is less sensitive to the length of cut variations as far as the cutting tool does not suffer the catastrophic
chipping in the cutting edges.
c. Minimum consumption in effective cutting power results when
the feed rate is in the range 0.1250.175 mm/rev of dry cutting
and 0.10.15 mm/rev of wet cutting.
d. Two-factor interaction models were seen accurate enough to
explain the interaction effects of cutting parameters on the effective cutting power.
3.1.3. Effect of independent cutting variables on the maximum
tool ank wear (VBmax )
Tool wear has a remarkable inuence in tool life, cutting forces,
vibration, quality of the machined surface and its dimensional accuracy, and consequently, the economics of cutting operations. In this
study off-line modeling of the maximum ank wear lands (VBmax )
are described as functions of independent cutting variables. Fig. 4c
depicts the interaction contour plots of VBmax as per RSM models
tabulated in Table 4. It can be found that:
a. During the course of the dry cutting of DSSs, an increased built
up edge formation on the tool, obvious inferior chip morphologies, more aggressive notch wear on the major and minor cutting
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8
48
EN 1.4462
6
43
EN 1.4410
Alternative Rank
37
31
25
19
13
7
1
1
11
13
15
17
19
21
23
2
25
27
29
31
33
35
37
39
9
41
43
45
4 7 48
Alternative
v No.
Fig. 5. Alternatives ranks.
(5)
Dry: R2 = 0.92
VBmax = 7.7696 (%Fr ) 18.549
(6)
R2
(7)
= 0.93
(8)
chips, whose edges are very sharp, could possibly endanger the
machine operator and cause safety risks [50]. In this study, utilizing the chip volume ratio R, the spatial requirement for the chips
is considered. Each chip form is assigned to a chip volume ratio
R, which denes by what factor the transport volume needed for
the specic chip form exceeds the intrinsic material volume of the
chip. According to these assignments, R 100 for snarled and ribbon chips, 60 R 100 for coiled, at helical and cylindrical helical
chips, 30 R 60 for short coiled chips, 10 R 30 for spiral chips
and 3 R 10 for short chip particles. It is clear from Fig. 5d that;
a. Higher values of cutting speeds and feed rates are necessary to
minimize the chip volume ratio.
b. In wet cutting of DSSs, friendlier-to-machine chip forms were
produced because of the less encountered friction in the contact
area between the chip and rake face.
c. Ribbon and snarled chip forms were common when the
metals are machined at feed rate and depth of cuts lower
than 0.15 mm/rev and 1 mm, respectively. At intermediate feed
ranges, the produced chips were rather of at-helical and
cylindrical-helical forms. The chip forms were rather short coiled
chips at higher feed ranges.
d. Under the same machining conditions which might produce
continuous chips, different chip forms were possible due to continuous entanglement of chips especially when Lc /ap 6.
e. Due to the higher proof and tensile strength, and, lower sulfur and
phosphor constituents to assist chip breaking, R values of cutting
EN 1.4410 were generally higher than of cutting EN 1.4462.
f. The tendency to enhance chip segmentation is expected to rise
when the chip curl radius is reduced, the coolant pressure is
increased and the coolant restricted to smaller area of the chip.
3.2. Parametric optimization of performance characteristics
The rst optimization process in this study is formulated as follows:
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Table 5
Optimization results.
Material
Process
condition
vc (m/min)
ap (mm)
Lc (mm)
%Fr
Pe (W)
VBmax (m)
1.5000
1.5000
1.5000
1.5000
12.0000
12.0000
12.0000
12.0000
6.0589
9.4987
14.8064
11.9899
2027.4
1578.7
1904.1
1142.4
104.3667
51.64860
108.0094
53.7075
73.4938
92.6377
99.2323
114.1464
0.1000
0.1372
0.1000
0.1163
1.5000
1.5000
1.5000
1.5000
12.0000
12.0000
12.0000
12.0000
19.1845
14.1790
22.4745
14.7725
824.876
1022.90
953.4741
964.9281
146.1453
69.7186
184.9923
84.5455
102.5605
124.5878
113.1389
141.0985
0.2388
0.1802
0.1600
0.1732
1.5000
1.5000
1.5000
1.5000
12.0000
12.0000
12.0000
12.0000
12.2771
10.4841
15.1967
12.0794
1861.6
1240.8
1965.8
1136.9
124.9669
47.4439
98.4184
49.9869
88.1069
111.8589
105.7843
118.4307
0.2500
0.2500
0.2432
0.2500
1.5000
1.5000
1.5000
1.5000
12.0000
12.0000
12.0000
12.0000
21.1169
32.1583
29.5881
40.2478
4151.2
4533.9
4299.4
5344.2
195.9552
210.0153
225.9687
259.3247
35.1433
19.6510
45.8620
8.9413
200.0000
200.0000
200.0000
200.0000
f (mm/rev)
3.2.3. Constraints
To ensure that the result of minimization of a performance will
not cause an excessive increase in the other three performances,
once a performance is selected as a primary objective the others are
selected as implicit constraints Cj . This is mathematically expressed
as below:
LBj Cj UBj
j=1:3
(9)
where LBj and UBj are lower and upper bounds of the implicit constraints which are selected based on practical considerations. In
this study, it would be appropriate when %Fr %Frmax . , Pe Pemax ,
VBmax VBmax(max) and R Rmax .
3.2.4. Optimization algorithm
For the purpose of nding minimum of constrained nonlinear multivariable functions described before, Cuckoo Search (CS)
algorithm was seen powerful enough to perform the task. The initializing optimization parameters for CS algorithms were: number
of nests (n) = 20 and probability (Pa ) = 0.25. The obtained optimization results showed that CS is highly reliable and converge
consistently to the optimum solution. In Table 5, the presented
results indicate a conicting inuence of the process parameter on
the performance characteristics in conjunction with the different
process conditions. As a summary, the following conclusion points
can be depicted from the table:
(10)
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10
(11)
The basic time tg is the sum of the main process time th and
auxiliary process time tn .
tg = th + tn
(12)
The main cutting time for constant cutting speed facing per
each cutting trial in Table 3 can be calculated using the following
expression:
KM =
th = tc + Cf
JAS =
(13)
1
JAS
(14)
(15)
Total setup time trB refers to the time required for machine setup tvM , tool change trW and nonproductive set-up activities trV . The
latter is often estimated as 30% of the machine set-up and tool
change time.
trB = tvM + trW + trV
(16)
(17)
where tWZ is the time that passes till a single tool is changed, and
both the position correction and positioning for re-entry have taken
place. The tool life T is calculated based on tool wear criteria of
VBmax = 600 m. The developed RSM models of VBmax are utilized
to nd the maximum allowable length of cuts Lcmax when VBmax
is 600 m. Once the length of cuts are determined, they are substituted into Eq. 14 to nd the tool life for each cutting trial. The
overall working time ta per x number of machines is described as:
ta = te
m
x
(18)
tbB = m 1.3
4000
f vc
+ Cf + tn
+ tWZ
t
h
T
tl
+ kbE
(21)
(22)
p
k
100 bB
(23)
(24)
To calculate the space cost kbR , planning estimations should consider the machine required area Q in m2 and the monthly rent A per
m2 :
kbR = 12 Q A
(25)
(26)
(27)
where Lm is the gross hourly wage and r as the amount of nonwage costs of the operator. It is appropriate when a new factor that
summarizes the machine cost and the wage rate per hour in terms
of previously dened time scales is formulated as:
KML = KM +
trB + ta
KL
tbB
(28)
The costs of typical indexable carbide cutting tools are comprised of the cost of tool holders kWH , inserts kWP and spare parts
kET :
KW = kWH + kWP + kET
(29)
+ trV + tvM
bB
4000
f vc
trW = m tWZ
k
Here, the cutting time tc is the time in which the tool is actually
cutting and determined by:
tc =
(20)
(19)
m th KWSP
0.8 T Zs
(30)
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in tool life. The spare parts costs are often expressed in terms of
percentage of the tool holder and insert costs. The nal production
cost per unit is obtained by adding the terms in Eqs. (20)(35):
1
m th KWSP
KF =
t KM + (trB + ta ) KL + kWH +
+ kET
m bB
0.8 T Zs
(31)
KM +
1
x
KL
th
11
(36)
(37)
(32)
1
m
KM +
1
KL
KL (trM + trV ) + KM +
x
x
th
1
(KM + KL )(tW ) + KW
T
m
(34)
(35)
Q = 40 m2
A = 30 D /m2 .Mo.
Ec = 0.130 D /kWh
kk = 0.90 D /h
Lm = 34 D /h
r = 2.5
kWH = 80D
Zs = 4
q = 10.5
KWSP = 6 D
x=1
PM = 25 kW
%C2 = 30
h/week = 40
week/annum = 40
working shifts/day = 1.9
(38)
Rij =
xij
(39)
x2
i=1 ij
vij = wj rij
(40)
v1 , v1 , , vj , , vn
v
, v
, , v
, , v
n
1
1
j
(41)
(42)
n
Si =
(vij v )2
i
(43)
j=1
n
2
S =
(vij v )
i
(44)
j=1
Si
Si
+ Si
(45)
i = 1, 2, . . ., m; 0 Ci 1
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Step 7. Rank the preference order, so that the alternative that has
the shortest distance to the ideal solution is ranked rst [17,52,53].
The data given in Table 3 are represented as matrix D48 4 for
each material case. The matrix is not shown here as it is nothing
but the repetition of data given in Table 3, which is represented in
a matrix form. The attribute weights for machine utilization time
tbB , main time-related costs K1 and the tool related costs K3 were
0.45, 0.3, 0.25, respectively. The normalized decision matrix and
then the weighted normalized matrix are determined by using Eqs.
(39) and (40) respectively. The positive ideal solution (A*) and the
negative ideal solution (A ) could be found by Eqs. (41) and (42).
Eqs. (43) and (44) are used to determine the separation measures.
Finally, Eq. (45) is utilized to calculate the relative closeness to the
ideal solution Ci . The results of performing TOPSIS are summarized
in Table 6.
The rankings of alternatives by their corresponding TOPSIS
indices (see Fig. 5.) revealed the favourability of adapting wet
cutting for a simultaneous minimization approach. This is mainly
attributed to the fact that when the components are dry machined
the cost of increasingly tool wear rate and power consumption
overtakes the advantage of not employing cutting uids. It is also
seen that the order of ranking of both materials is almost identical.
Because of the higher effective power consumption and tool wears
rate at higher cutting speed and higher feed rate ranges and the
worst chip morphology at lower ranges, an intermediate range has
given the preference over both ranges. It is also noticed that the
lower cutting speed when dry cutting EN 1.4410 and the higher
cutting speed when wet cutting EN 1.4462 has given higher preference than the similar dry cutting EN 1.4462 and wet cutting EN
1.4410, respectively.
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EN 1.4462
EN 1.4410
vc (m/min)
f (mm/r)
ap (mm)
Lc (mm)
Cutting cond.
tbB h/year
K1 D /unit
K3 D /unit
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
200
75
75
200
200
200
75
137.5
75
200
75
200
200
200
75
75
75
200
200
200
75
137.5
137.5
75
75
137.5
200
106.25
137.5
200
75
200
200
75.0
137.5
200
75
168.75
75
200
200
137.5
200
75
75
75
75
200
0.25
0.25
0.25
0.25
0.25
0.10
0.17
0.17
0.25
0.10
0.10
0.25
0.10
0.10
0.25
0.10
0.25
0.25
0.25
0.25
0.10
0.17
0.17
0.25
0.10
0.10
0.10
0.21
0.10
0.25
0.17
0.17
0.17
0.10
0.25
0.10
0.10
0.14
0.17
0.10
0.25
0.25
0.10
0.25
0.10
0.25
0.10
0.17
1.5
1.5
1.5
0.5
0.5
0.5
1
1.5
1
1.5
1.5
0.5
1.5
0.5
1.5
0.5
0.5
1.5
1
1.5
1.5
1
1
0.5
0.5
1
1.5
0.75
1.5
1.5
1.5
1
1.5
0.5
1.5
0.5
1
0.75
0.5
0.5
0.5
0.5
1
0.5
0.5
0.5
1.5
0.5
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
Wet
Dry
Wet
Wet
Wet
Wet
Wet
Wet
Dry
Wet
Wet
Wet
Wet
Wet
Wet
Dry
Wet
Dry
Dry
Wet
Wet
Wet
Wet
Wet
Wet
Wet
Dry
Dry
Dry
Dry
Dry
Wet
Dry
Dry
Dry
Dry
Dry
Dry
Dry
Dry
Dry
Dry
Dry
Wet
Wet
Dry
Dry
Dry
734.477
959.736
959.220
1261.236
1261.236
1969.404
1496.224
877.472
1230.424
943.050
1562.386
1261.236
943.050
1969.404
959.220
3910.637
1990.176
748.012
901.821
734.477
1562.386
1095.527
1095.527
1990.176
3842.968
1443.586
992.902
1379.183
1140.819
748.012
1155.752
956.205
819.295
3910.637
791.462
2082.064
2173.947
1383.132
2614.182
2082.064
1334.430
1497.952
1272.385
1990.176
3842.968
2026.145
1588.641
1558.531
2.543
4.880
4.910
7.629
7.629
14.652
10.138
4.205
7.320
4.884
10.802
7.629
4.884
14.652
4.910
32.207
14.730
2.527
3.791
2.543
10.802
6.308
6.308
14.730
32.405
9.692
4.854
8.578
6.422
2.527
6.717
4.916
3.257
32.207
3.155
14.562
16.104
8.394
20.151
14.562
7.582
9.464
7.281
14.730
32.405
14.640
10.736
9.772
1.581
1.043
1.035
1.334
1.334
0.587
0.688
0.884
1.270
0.752
0.600
1.334
0.752
0.587
1.035
1.882
0.850
1.862
2.266
1.581
0.600
0.788
0.788
0.850
0.459
0.572
1.800
1.581
1.397
1.862
1.050
0.958
1.726
1.882
1.370
2.957
1.435
2.075
1.625
2.957
2.871
2.094
2.240
0.850
0.459
1.605
1.151
2.678
0.845
0.885
0.886
0.791
0.791
0.609
0.749
0.918
0.804
0.914
0.729
0.791
0.914
0.609
0.886
0.389
0.604
0.813
0.764
0.845
0.729
0.869
0.869
0.604
0.370
0.766
0.800
0.748
0.814
0.813
0.838
0.894
0.825
0.389
0.869
0.566
0.558
0.715
0.472
0.566
0.675
0.693
0.723
0.604
0.370
0.592
0.714
0.653
tbB h/year
K1 D /unit
K3 D /unit
Ci
748.025
985.958
971.803
1288.984
1288.984
1985.940
1512.126
884.971
1252.431
952.169
1571.265
1288.984
952.169
1985.940
971.803
3922.912
2016.453
795.556
942.674
748.025
1571.265
1109.346
1109.346
2016.453
3860.786
1455.102
1031.209
1402.554
1167.960
795.556
1178.422
972.606
860.453
3922.912
826.793
2128.465
2188.291
1412.783
2631.993
2128.465
1383.321
1530.679
1305.274
2016.453
3860.786
2047.829
1608.526
1603.641
2.543
4.880
4.910
7.629
7.629
14.652
10.138
4.205
7.320
4.884
10.802
7.629
4.884
14.652
4.910
32.207
14.730
2.527
3.791
2.543
10.802
6.308
6.308
14.730
32.405
9.692
4.854
8.578
6.422
2.527
6.717
4.916
3.257
32.207
3.155
14.562
16.104
8.394
20.151
14.562
7.582
9.464
7.281
14.730
32.405
14.640
10.736
9.772
1.866
1.595
1.300
1.919
1.919
0.936
1.023
1.042
1.733
0.945
0.787
1.919
0.945
0.936
1.300
2.141
1.405
2.862
3.125
1.866
0.787
1.079
1.079
1.405
0.835
0.814
2.606
2.072
1.968
2.862
1.527
1.304
2.592
2.141
2.114
3.933
1.737
2.699
2.000
3.933
3.900
2.783
2.932
1.405
0.835
2.062
1.570
3.627
0.886
0.882
0.904
0.792
0.792
0.607
0.748
0.941
0.810
0.924
0.728
0.792
0.924
0.607
0.904
0.385
0.602
0.799
0.771
0.886
0.728
0.873
0.873
0.602
0.373
0.765
0.799
0.758
0.818
0.799
0.839
0.904
0.817
0.385
0.860
0.569
0.561
0.728
0.472
0.569
0.681
0.701
0.737
0.602
0.373
0.595
0.716
0.658
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Component
Ci
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Independent variables
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Table 6
Results of multi-objective optimization using TOPSIS.
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1
1 + exp[(b +
wi xi )]
(46)
wi xi
(47)
where w an b are the weights and biases of the network respectively. To facilitate the neural network training process, all the
inputs were normalized using the following equation:
2(x xmin )
xi =
1
(xmax xmin )
(48)
This normalization maps all the inputs and OSI between 1 and
+1. The ANN architecture consists of 4 neurons in the input layer, 1
neuron in the output layer. The weights and biases of the network
are initialized to small random values to avoid immediate saturation in the respective functions. The network was trained by using
gradient descendent with momentum back propagation algorithm.
In this algorithm four parameters must be tuned: learning rate LR ,
momentum constant Mc , training epochs Ep and number of hidden
neurons Hn . For this tuning the Taguchi design L9 (34 ) was used to
nd the most convenient values for achieving no only lower root
mean square, but also good generalization capability, giving the
following values: LR = 0.0705, Mc = 0.5895, Ep = 5000 and Hn = 7. The
performance of the ANNs was statistically measured by the root
mean squared error (RMSE), the coefcient of determination (R2 )
and the absolute average deviation ( avg ) obtained as follows:
n
1
RMSE =
[(yactual )i (ypredicted ) ]2
i
(49)
i=1
R2 = 1
n
[(yactual )i (ypredicted )i ]2
i=1
n
2
i=1
[(yactual )i (ymean )i ]
(50)
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15
f
ap
Neural Network
Model
Lc
OSI
Cuckoo Search
Algorithm
Independent Variables
Maximum
OSI
Fig. 9. Cuckoo Search Neural Network System.
Fig. 10. Maximization of OSI with CSNNS.
avg
1
=
n
n
(yactual )i (ypredicted )i
100
(yactual )i
(51)
i=1
where yactual represents the actual, ypredicted obtained by neural network and ymean the mean of actual OSI values respectively, and n
is the number of experimentation trials. It must be remarked that
number of hidden neurons guarantee that there are more training
samples than the total amount of free parameters, thus the training process is mathematically determined. The R-squared statistics
of the models were generally greater than 0.99, which indicate
that the models as tted explain over 99% of the variability in
OSI. The trained networks achieved RSME and avg values below
target (0.0001) and (1%) respectively. It must be mentioned that
the relationships between variables are complex, which prove the
application of articial neural networks very advantageous.
Neural network models are then integrated with the cuckoo
search optimization algorithm, so that solutions which will provide
useful information to the user during the selection of machining
parameters are obtained. The architecture of the cuckoo search
neural network system (CSNNS) is shown in Fig. 9. CS outperforms
many existing algorithms such as genetic algorithm and particle
swarm optimization. This superiority can be attributed to the fact
that cuckoo search uses a combination of vectorized mutation,
crossover by permutation and Levy ights and selective elitism
among the best solutions. In addition, the not-so-good solutions
can be replaced systematically by new solutions, and new solutions
are often generated by preferring quality solutions in the solution
sets. Thus, the mechanism of the overall search moves is more subtle and balanced, compared with the simple mechanism used in
particle swarm optimization [58]. The number of host nests (or the
population size n) and the probabilities (Pa ) were tuned using trial
and error method. The population size of (25) and probability of
(0.25) were found sufcient in this case.
The selected decision variables were cutting parameters for each
process condition. They were dened for the ranges between the
minimum and maximum experimental levels presented in Table 2.
OSIs were selected as the objective functions to maximize:
OSIi =
i (vc , f, ap , Lc )
(52)
0.032f 2
r
(53)
Table 7
Results of CSNNS.
Material
Process condition
vc (m/min)
f (mm/rev)
ap (mm)
Lc (mm)
EN
1.4462
Wet
Dry
156.283
91.793
0.1359
0.1848
1.500
1.500
12
12
EN
1.4410
Wet
Dry
146.30
82.3259
0.1286
0.2019
1.500
1.500
12
12
%Fr
6.6477
9.9772
14.878
13.204
Pe (W)
VBmax (m)
OSI
2218.1
1354.6
104.19
48.049
69.073
105.6
0.7105
0.6411
2066.7
1.4175
106.401
62.135
97.052
100.7
0.6969
0.6106
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4. Conclusions
Machining of duplex stainless steel grades such as EN 1.4462
and EN 1.4410 DEDM has been systematically investigated under
a multi-pass constant cutting speed facing operation. In the rst
phase of the investigation, D-optimal experimental design is used
extensively to investigate the effect of process variables on performance characteristics such as percentage increase in radial cutting
forces, effective cutting power, maximum tool ank wear and chip
volume ratio. Based on RSM, effective empirical relationships to
predict performance characteristics at 95% condence level were
developed. ANOVA used to check the adequacy of the models. The
models were then analyzed using 3D surface graphs and used to
study the interaction effects of process parameters. At the end of
the rst phase, constrained cuckoo search algorithm is selected to
perform optimization of the performance characteristics thereby
dening the optimum process conditions. The following general
conclusions can be drawn from the rst phase of the investigation:
a. The values of obtained %Fr when EN 1.4410 steels are cut were
higher than EN 1.4462 steels. They have shown direct linear
correlations with maximum tool ank wear and proportional
dependency on Lc /ap ratio, and approached their minimum values as cutting speed and feed rate increased to certain specied
limit. However, when the materials are cut dry, lower cutting
speed and feed rates than wet cutting are preferred to minimize
%Fr .
b. Generally, the two-factor interaction models were seen accurate
enough to explain the dependency relation between effective cutting power and independent variables. Their minimum
consumption were seen when the feed rate is in the range
0.1250.175 mm/rev of dry cutting and 0.10.15 mm/rev of wet
cutting and the rest of the remained independent variables are
kept at their lowest levels.
c. Wet cutting at cutting parameter ranges of vc 100160 m/min,
f 0.150.25 mm/rev, ap 0.751 mm for machining EN
1.4462
and
vc 120160 m/min, f 0.150.20 mm/rev,
ap 1.251.5 mm for machining EN 1.4462 were seen optimum in minimizing the tool ank wear. Dry machining
is possible when cutting parameters are set appropriately. The settings include; machining of EN 1.4462 at
vc 75110 m/min,
f 0.150.2 mm/rev,
ap 11.5 mm
and maximum Lc /ap 6, and machining of EN 1.4410 at
vc 7590 m/min, f 0.1250.175 mm/rev, ap 0.81.35 mm
and maximum Lc /ap 4.
d. Ribbon and snarled chip forms were common when the DSSs are
machined at feed rate and depth of cuts lower than 0.15 mm/rev
and 1 mm, respectively. In wet cutting, friendlier-to-machine
chip forms were produced and the R values of cutting EN 1.4410
were generally seen higher than of cutting EN 1.4462. Under the
same machining conditions which might produce continuous
chips, different chip forms were also possible, especially when
Lc /ap 6.
In the second phase of the study, the measurements were used
to develop a comprehensive machining economics model. A case
study of producing 12000 units of per each experimental run is
considered and the corresponding machining costs and production rates were determined. Summarizing the conclusion points
depicted at this stage:
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Please cite this article in press as: Koyee RD, et al. Modeling and optimization of turning duplex stainless steels. J Manuf Process (2014),
http://dx.doi.org/10.1016/j.jmapro.2014.05.004