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ABSTRACT
Metal machining has been an interesting topic of
research for decades. Early research efforts include
topics, such as, chip formation, heat generation at toolchip and tool-work interfaces, tool wear, tool life,
cutting force analysis, machinability, power
requirements, manufacturing cost and productivity etc.
With more emphasis on quality of surface finish with
high production rate, in past few decades, research
efforts seem to have been diverted towards the study of
surface finish/roughness in metal machining.
The objectives of the present study is the development
of the surface roughness prediction model using
Artificial neural network in terms of feed, cutting
speed and depth of hole during the drilling of AISI
1020 steel and to Investigate the effect of drilling
parameters on surface roughness using 3D plots
between the parameters and surface roughness .
In the present research a multilayer feed-forward
neural network has been employed using MATLAB
software. The input layer has four neurons
corresponding to each of the three input variables
(cutting speed, feed and depth of cut) and one neuron
in the output layer corresponding to output variable
(surface roughness). The number of hidden layers and
neurons in hidden layers has been determined on the
basis of trial and error method. The mean square error
has been selected as performance function. The ANN
training simulation was carried out using batch
gradient descent with variable learning rateprocedure
traingdx. This procedure helps in improving the
performance of back -propagation algorithm by
allowing the learning rate to change during the training
process based on the complexity of the local error
surface, In this research, a portable surface roughness
tester has been used to measure surface roughness
indicators of finished work pieces.
Keywords: Artificial neural
roughness, AISI 1020 steel.
I.
network,
surface
INTRODUCTION
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853
International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 0882
Volume 4, Issue 8, August 2015
V.
EXPERIMENTAL WORK
II.
OBJECTIVES
Development of the surface roughness
prediction model using Artificial neural
network in terms of feed, cutting speed and
depth of hole during the drilling of AISI 1020
steel.
Investigating the effect of drilling parameters
on surface roughness using 3D plots between
the parameters and surface roughness.
To investigate the most significant parameters
that affects the surface roughness.
III.
IV.
PROPOSED
MODELS
NEURAL
NETWORK
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854
International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 0882
Volume 4, Issue 8, August 2015
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6
7
8
9
10
11
12
13
14
15
16
17
18
19
600
300
600
600
300
900
600
300
600
900
900
900
900
600
300
0.01
0.02
0.03
0.02
0.01
0.01
0.03
0.01
0.02
0.02
0.03
0.03
0.03
0.03
0.02
20
10
10
10
15
15
20
20
20
20
10
20
15
15
15
1.021
1.207
1.133
1.011
1.301
1.311
1.527
1.485
1.229
1.782
1.608
2.182
1.811
1.342
1.474
0.25258
0.37232
0.32468
0.24614
0.43283
0.43927
0.57833
0.55129
0.38648
0.74249
0.63047
1.00000
0.76116
0.45923
0.54421
10
20
10
15
1.259
1.972
1.182
1.199
0.40579
0.86481
0.35622
0.36717
Spindle
speed
600
300
900
900
600
300
600
600
300
900
600
300
600
900
900
900
900
600
300
900
300
300
600
300
900
600
300
feed
0.01
0.02
0.01
0.02
0.01
0.02
0.03
0.02
0.01
0.01
0.03
0.01
0.02
0.02
0.03
0.03
0.03
0.03
0.02
0.02
0.03
0.01
0.02
0.03
0.01
0.01
0.03
Depth
of hole
15
20
10
15
20
10
10
10
15
15
20
20
20
20
10
20
15
15
15
10
20
10
15
10
20
10
15
DEVELOPMENT OF ANN
SURFACE ROUGHNESS:
SN
Spindle
speed
feed
Depth
Of
hole
S/R
1
2
3
4
600
300
900
900
0.01
0.02
0.01
0.02
15
20
10
15
0.982
1.653
1.118
1.498
24
25
26
27
0.03
0.01
0.01
0.03
10
20
10
15
1.54
1.438
0.784
1.774
Training parameters
Values
Network configuration
4-11-1
NOR
S/R
0.22747
0.65944
0.31502
0.55966
300
900
600
300
0.58670
0.52103
0.10000
0.73734
FOR
0.02
0.03
0.01
0.02
Surface
roughnes
0.982
1.653
1.118
1.498
1.021
1.207
1.133
1.011
1.301
1.311
1.527
1.485
1.229
1.782
1.608
2.182
1.811
1.342
1.474
1.259
1.972
1.182
1.199
1.54
1.438
0.784
1.774
MODEL
900
300
300
600
TRAINING OF MODEL:
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1
10000
0.00001
0.03
1.001
4
0.43
1.00E-04
19
4
4
855
International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 0882
Volume 4, Issue 8, August 2015
VALIDATION OF MODEL:
TESTING OF MODEL:
Performance of the network:
OF
Spindle
speed
600
300
900
900
600
PREDICTED
ROUGHNESS:
feed
0.01
0.02
0.01
0.02
0.01
Depth
of hole
15
20
10
15
20
EXP.
S/R
0.982
1.653
1.118
1.498
1.021
SURFACE
PRD.
S/R
0.926
1.699
1.093
1.503
1.044
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International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 0882
Volume 4, Issue 8, August 2015
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7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
300
600
600
300
900
600
300
600
900
900
900
900
600
300
900
300
300
600
300
900
600
300
0.02
0.03
0.02
0.01
0.01
0.03
0.01
0.02
0.02
0.03
0.03
0.03
0.03
0.02
0.02
0.03
0.01
0.02
0.03
0.01
0.01
0.03
10
10
10
15
15
20
20
20
20
10
20
15
15
15
10
20
10
15
10
20
10
15
1.207
1.133
1.011
1.301
1.311
1.527
1.485
1.229
1.782
1.608
2.182
1.811
1.342
1.474
1.259
1.972
1.182
1.199
1.54
1.438
0.784
1.774
1.237
1.077
1.021
1.361
1.295
1.574
1.467
1.272
1.742
1.613
2.156
1.841
1.334
1.403
1.271
1.886
1.116
1.207
1.568
1.480
0.839
1.794
EFFECT OF DRILLING
PARAMETERS ON S/R:
857
International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 0882
Volume 4, Issue 8, August 2015
VI.
REFERENCESES
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Prakash, M.K. (2010). Drilling of hybrid Al-5%SiCp5%B4Cp metal matrix composites, International
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49(9-12), 871-877.
[2] Bahce, E. and Ozel, C. (2013). experimental
investigation of the effect of machining parameters on
the surface roughness and the formation of built up
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[3] Bai, B. H., Kumar, G.V. and Babu, K.A.(2014).
Optimization of surface roughness and burr height in
drilling of AL-6061 under MQL condition using DFA,
Mechanica Confab, 3(4), 10-17.
[4] Cicek, A. (2007), Step based geometric and
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[5] Cicek, A., Kivak, T. and Samtas, G. (2012).
Application of Taguchi method for surface roughness
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Steel, Journal of Mechanical Engineering, 58(3), 122129.
[6] Davim J.P. and Reis, P. (2003). Study delamination
in drilling carbon fiber reinforced plastics (CFRP)
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Campus Santiago, Portugal. 59, 481-487.
[7] Gaitonde V.N. Karnik S.R., Acyutha B.T. and
Siddeswarappa B. (2007). Methodology of Taguchi
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minimize burr size. International J. Advance
Manufacturing Technology, 34, 1-8.
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International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 0882
Volume 4, Issue 8, August 2015
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