Application of ANN to estimate surface roughness using cutting parameters, force, sound and vibration in turning of Inconel 718

Abstract

In this paper, artificial neural network approach is used to predict surface roughness using cutting parameters, force, sound and vibration in turning of Inconel 718. Experiments were performed by using cryogenically treated and untreated inserts, and various responses were measured. Then, these measured responses were used as input to the artificial neural network to predict surface roughness. It is found that the models developed by artificial neural network are predicting surface roughness with more than 98% accuracy. Further, the predictions obtained by artificial neural network are compared with the results of regression-based prediction models earlier proposed by the authors. The modified regression models were estimating surface roughness with more than 90% accuracy. Based on correlation coefficient values, the prediction results of modified regression model are compared with those obtained by artificial neural network. Finally, it is concluded that artificial neural network models are better for estimating surface roughness than the regression models and such predictions are useful for real-time control of the process to acquire the desired surface roughness. Keywords Artificial neural network • Surface roughness • Inconel 718 Abbreviations CNC Computer numerical control RSM Response surface methodology FOE M Modified first-order equation ANN Artificial neural network BP Backpropagation BR Bayesian regularization LM Levenberg-Marquardt AE Absolute error (%) MAE Mean absolute error (%) MSE Mean square error (%) List of symbols v Cutting speed (m/min) f Feed rate (mm/rev) d Depth of cut (mm) F c Cutting force (N) S Sound pressure level (Pa) V v Vibration velocity of workpiece (m/s) n Number of experiments R ai Average of measured surface roughness in μm R ai Estimated surface roughness h Number of neurons in single hidden layer R 2 Correlation coefficient

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