Sustainable manufacturing is one of the most important and most challenging issues in present industrial scenario. With the intention of diminish negative effects associated with cutting fluids, the machining industries are continuously developing technologies and systems for cooling/lubricating of the cutting zone while maintaining machining efficiency. In the present study, three regression based machine learning techniques, namely, polynomial regression (PR), support vector regression (SVR) and Gaussian process regression (GPR) were developed to predict machining force, cutting power and cutting pressure in the turning of AISI 1045. In the development of predictive models, machining parameters of cutting speed, depth of cut and feed rate were considered as control factors. Since cooling/lubricating techniques significantly affects the machining performance, prediction model development of quality characteristics was performed under minimum quantity lubrication (MQL) and high-pressure coolant (HPC) cutting conditions. The prediction accuracy of developed models was evaluated by statistical error analyzing methods. Results of regressions based machine learning techniques were also compared with probably one of the most frequently used machine learning method, namely artificial neural networks (ANN). Finally, a metaheuristic approach based on a neural network algorithm was utilized to perform an efficient multi-objective optimization of process parameters for both cutting environment.

In industry, the capability to predict the tool point frequency response function (FRF) is an essential matter in order to ensure the stability of cutting processes. Fast and accurate identification of contact parameters in spindle-holder-tool assemblies is very important issue in machining dynamics analysis. This work is an attempt to illustrate the utility of soft computing techniques in identification and prediction contact parameters of spindle-holder-tool assemblies. In this paper, three soft computing techniques, namely, genetic algorithm (GA), simulated annealing (SA), and particle swarm optimization (PSO) were used for identification of contact dynamics in spindle-holder-tool assemblies. In order to verify the proposed identification approaches, numerical and experimental analysis of the spindle-holder-tool assembly was carried out and the results are presented. Finally, a model based on the adaptive neural fuzzy inference system (ANFIS) was used to predict the dynamical contact parameters at the holder-tool interface of a spindle-holder-tool assembly. Accuracy and performance of the ANFIS model has been found to be satisfactory while validated with experimental results.

With the development of high-performance CNC machine tools, milling has been established as one of the main means of machining thin-walled parts. Thus, the selection of process parameters for milling operations is an important issue in end milling of thin-walled parts to assure product quality and increase productivity. The current study explores three machining parameters, namely wall thickness, feed, and machining strategies, that influence dimensional and form errors, surface roughness, and machining time milling of 7075-T6 aluminum alloy thin-walled parts. The effects of machining parameters on each of the response variables were analyzed using graphs of the main effects and three-dimensional surface plots. Analysis of the results show that the most influential factor for wall thickness deviation, dimensions deviation, perpendicularity deviation, flatness deviation, surface roughness of inner walls, surface roughness of outer walls, and surface roughness of reference plane was machining strategy, while feed is the most influential parameter affecting the machined time, followed by the machining strategy. The desirability concept has been used for simultaneous optimization in terms of machining parameters of the thin-walled parts machining process. Finally, a confirmation test with the optimal parameter settings was carried out to validate the results.

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