Experimental Investigation and Optimization of Turning Polymers Using RSM, GA, Hybrid FFD-GA, and MOGA Methods

Abstract

The machining of polymers has become widely common in several components of industry 4.0 technology, i.e., mechanical and structural components and chemical and medical instruments, due to their unique characteristics such as: being strong and light-weight with high stiffness, chemical resistance, and heat and electricity insolation. Along with their properties, there is a need to attain a higher quality surface finish of machined parts. Therefore, this research concerns an experimental and analytical study dealing with the effect of process parameters on process performance during the turning two different types of polymers: high-density polyethylene (HDPE) and unreinforced polyamide (PA6). Firstly, the machining output responses (surface roughness (Ra), material removal rate (MRR), and chip formation (λc)) are experimentally investigated by varying cutting speed (vc), feed rate (f), and depth of cut (d) using the full factorial design of experiments (FFD). The second step concerns the statistical analysis of the input parameters’ effect on the output responses based on the analysis of variance and 3D response surface plots. The last step is the application of the RSM desirability function, genetic algorithm (GA), and hybrid FFD-GA techniques to determine the optimum cutting conditions of each output response. The lowest surface roughness for HDPE was obtained at vc = 50 m/min, f = 0.01 mm/rev, and d = 1.47 mm and for PA6 it was obtained at vc = 50 m/min, f = 0.01 mm/rev, and d = 1 mm. The highest material removal rate was obtained at vc = 150 m/min, f = 0.01 mm/rev, and d = 1.5 mm for both materials. At f = 0.01 mm/rev, d = 1.5 mm, and vc = 100 for HDPE, and vc = 77 m/min for PA6, the largest chip thickness ratios were obtained. Finally, the multi-objective genetic algorithm (MOGA) methodology was used and compared.

Manufacturing of testing specimens from tough HDPE-100 pipe: Turning parameters optimization

“…In other words, disproportionate viscous-plastic scaling or tearing, at a high Vc, can be drastically limited by evacuating the heat generated by friction. The effects of rake angle (γ), feed rate (f) and some molecular properties are also discussed for others polymers [25][26][27][28]31,32].…”

“…It is also accepted that the higher the speed, the less substantial the plastic comportment is. The flow of plastically deformed lateral material of the workpiece along cutting-edge direction can enhance peaks heights and valleys depths of surface irregularities [13,14,23,32]. As shown in Fig.…”

Mathematical Modeling Using ANN Based on k-fold Cross Validation Approach and MOAHA Multi-Objective Optimization Algorithm During Turning of Polyoxymethylene POM-C

“…All experimental tests and survey results highlighted that the feed is the primary factor influencing the arithmetic mean roughness 𝑅𝑎, contributing 65.9% and 99.1%, respectively. In the literature, several studies [17][18][19][20][21] have explored the impact of machining conditions on engineering plastics, focusing on output parameters like surface texture, cutting temperature, material removal rate, viscous deformation, crystallinity rate, cutting forces, and cutting power. A recent study by Azzi et al [17] determined that the optimal parameters for minimizing𝑅𝑎and maximizing 𝑀𝑅𝑅 during the turning of polytetrafluoroethylene polymer (PTFE) are 𝑎𝑝 = 2 𝑚𝑚, 𝑓 = 0.126 𝑚𝑚/𝑟𝑒𝑣, and 𝑉 𝑐 = 270 𝑚/𝑚𝑖𝑛.…”

Comparative study of turning two engineering plastics (POM-C and PA-6) and optimisation using GA, SA, GRA and COPRAS with and without weighting (Entropie, critic, Swara, ROC)

“…Tabacaru et al [6] conducted a study on predicting roughness during dry drilling of polymeric materials such as high-density polyethylene (HDPE 1000 grade), polyamide (PA-6 grade), and polyacetal (POM-C grade). Alateyah et al [7] performed an experimental and analytical study investigation on the influence of cutting parameters on the turning of two different polymers types: high-density polyethylene (HDPE) and un-reinforced polyamide (PA-6). The results show that Ra increases with (Vc) and (f); however, an increase in (ap) generates better surface quality.…”