Comparison of NSGA-II, MOALO and MODA for Multi-Objective Optimization of Micro-Machining Processes

The popularity of micro-machining is rapidly increasing due to the growing demands for miniature products. Among different micro-machining approaches, micro-turning and micro-milling are widely used in the manufacturing industry. The various cutting parameters of micro-turning and micro-milling has a significant effect on the machining performance. Thus, it is essential that the cutting parameters are optimized to obtain the most from the machining process. However, it is often seen that many machining objectives have conflicting parameter settings. For example, generally, a high material removal rate (MRR) is accompanied by high surface roughness (SR). In this paper, metaheuristic multi-objective optimization algorithms are utilized to generate Pareto optimal solutions for micro-turning and micro-milling applications. A comparative study is carried out to assess the performance of non-dominated sorting genetic algorithm II (NSGA-II), multi-objective ant lion optimization (MOALO) and multi-objective dragonfly optimization (MODA) in micro-machining applications. The complex proportional assessment (COPRAS) method is used to compare the NSGA-II, MOALO and MODA generated Pareto solutions.

Experimental Investigation of Electrochemical Micro Turning of Ti6Al4V With NaOH Solution

Ti6Al4V is a highly favorable material in biomedical, aerospace and many other industries. However, rapid tool wear during machining has made Ti6Al4V into a difficult-to-machine material. Electrochemical machining may be a solution to that challenge. Moreover, high chemical affinity and formation of oxide layer over the surface have limited the application electrochemical machining for Ti6Al4V. In this paper, an experimental approach of electrochemical micro turning of Ti6Al4V has been described. The electrolyte was 10% aqueous solution of NaOH and the tool was SS 310. For each and every experiment workpiece rotational speed and machining time were kept constant. Constant DC voltage was applied and the inter-electrode gap between tool and workpiece was kept constant for each experiment. Experiments were performed using two different levels of applied voltage, axial feed rate and inter-electrode gap. Their effects over MRR and surface roughness have been determined. Additionally, the optimum working condition was determined in order to maximize MRR and minimize surface roughness. For each experiment, acceptable material removal and good surface finish have been achieved. The maximum surface roughness (Ra) was found 1.128 μm in experiment 1. The utilization of NaOH solution has resulted in controlled electrolyzing current, controlled material removal and therefore, good surface finish.

Investigations on Surface Roughness and Tool Wear Characteristics in Micro-Turning of Ti-6Al-4V Alloy

Micro-turning is a micro-mechanical cutting method used to produce small diameter cylindrical parts. Since the diameter of the part is usually small, it may be a little difficult to improve the surface quality by a second operation, such as grinding. Therefore, it is important to obtain the good surface finish in micro turning process using the ideal cutting parameters. Here, the multi-objective optimization of micro-turning process parameters such as cutting speed, feed rate and depth of cut were performed by response surface method (RSM). Two important machining indices, such as surface roughness and material removal rate, were simultaneously optimized in the micro-turning of a Ti6Al4V alloy. Further, the scanning electron microscope (SEM) analysis was done on the cutting tools. The overall results depict that the feed rate is the prominent factor that significantly affects the responses in micro-turning operation. Moreover, the SEM results confirmed that abrasion and crater wear mechanism were observed during the micro-turning of a Ti6Al4V alloy.