Modeling and Optimal Design of Machining-Induced Residual Stresses in Aluminium Alloys Using a Fast Hierarchical Multiobjective Optimization Algorithm

Abstract

The residual stresses induced during shaping and machining play an important role in determining the integrity and durability of metal components. An important issue of producing safety critical components is to find the machining parameters that create compressive surface stresses or minimise tensile surface stresses. In this paper, a systematic data-driven fuzzy modelling methodology is proposed, which allows constructing transparent fuzzy models considering both accuracy and interpretability attributes of fuzzy systems. The new method employs a hierarchical optimisation structure to improve the modelling efficiency, where two learning mechanisms cooperate together: NSGA-II is used to improve the model's structure while the gradient descent method is used to optimise the numerical parameters. This hybrid approach is then successfully applied to the problem that concerns the prediction of machining induced residual stresses in aerospace aluminium alloys. Based on the developed reliable prediction models, NSGA-II is further applied to the multiobjective optimal design of aluminium alloys in a 'reverse-engineering' fashion. It is revealed that the optimal machining regimes to minimise the residual stress and the machining cost simultaneously can be successfully located.

Data‐Driven Pareto Optimization for Microalloyed Steels Using Genetic Algorithms

“…The efficacy of data‐driven modeling1–4 and the multi‐objective optimization using Genetic Algorithms5 is now firmly established for the systems of materials interest 6–8. Data‐driven model often implies constructing an empirical description of the system utilizing the available experimental information.…”

Stress Distribution in Silicon Subjected to Atomic Scale Grinding with a Curved Tool Path

“…In contrast, compressive residual stress is beneficial to enhancing structural integrity and durability [8,9], which is beneficial to the functional performance of the final component. Accordingly, contemporary techniques usually seek to increase compressive residual stress in the field of ultraprecision machining by trial, such as polishing, shot peening, abrading and heat treatment [9,10]. However, the fundamental mechanism of residual stress generation and evolution is still not clear.…”

Multiobjective optimal design of friction stir welding considering quality and cost issues

“…[1][2][3][4][5] In the review article, Tutum and Hattel 6 have foreseen a bright perspective of implementing soft computing based optimisation approaches into the FSW design and suggested some practical directions for the future research. However, only few works have been carried out in this area.…”