Modelling and optimisation of surface roughness from microgrinding of nickel-based single crystal superalloy using the response surface methodology and genetic algorithm

Zhou, Yunguang; Gong, Yadong; Zhu, Zongxiao; Gao, Qi; Wen, Xuelong

doi:10.1007/s00170-015-8121-z

Cited by 28 publications

(5 citation statements)

References 17 publications

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“…According to results, presented method was determined as successfully for multi-axis ball-end milling process. Zhou et al (2016) used response surface methodology and genetic algorithm to optimize the surface roughness of nickel-based single crystal superalloy using microgrinding process. According to verification results, optimum parameter levels were found as reliable.…”

Section: Introductionmentioning

confidence: 99%

Optimization of wood machining parameters in CNC routers: Taguchi orthogonal array based simulated angling algorithm

Hazır

Koç

2019

Maderas, Cienc. tecnol.

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In the present study, two mathematical models were developed to optimize the surface roughness for machining condition of Cedar of Lebanon pine (Cedrus libani). Taguchi approach was applied to examine the effect of CNC processing variables. Quality characteristics parameters were selected as arithmetic average roughness (R a) and average maximum height of the profile (R z) for wood material. Analysis of variance (ANO-VA) was used to determine effective machining parameters. Developed mathematical models using response surface methodology (RSM) were optimized by a combined approach of the Taguchi's L 27 orthogonal array based simulated angling algorithm (SA). Optimum machining levels for determining the minimum surface roughness values were carried out three stages. Firstly, the desirability function was used to optimize the mathematical models. Secondly, the results obtained from the desirability function were selected as the initial point for the simulated angling algorithm. Finally, the optimum parameter values were obtained by using simulated angling algorithm. Minimum R a value was obtained spindle speed of 17377 rpm, feed rate of 2,012 m/min, tool radius of 8 mm and depth of cut of 2,009 mm by using desirability function based simulated angling algorithm. For R z these results were found as 16980 rpm, 2,004 m/min, 8,001 mm and 2,003 mm. The R-square values of the R a and R z were 95,91 % and 96,12 %, respectively. The proposed models obtained the minimum surface roughness values and provided better results than the observed values.

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Section: Introductionmentioning

confidence: 99%

Optimization of wood machining parameters in CNC routers: Taguchi orthogonal array based simulated angling algorithm

Hazır

Koç

2019

Maderas, Cienc. tecnol.

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“…This classification of tools that are useful for digital twins and automated decision making is complemented by other methods, indicatively Taguchi methodology (impact study), 55 Tikhonov regularization for inverse physics models 56,57 and for optimization techniques. 58 In the context of digital twins, empirical models (also known as surrogate) can be used for fast decision making. The way these are integrated are either to substitute theoretical models, or as plain data driven models, estimated by measurements.…”

Section: Data Driven Modelsmentioning

confidence: 99%

Designing a digital twin for micromanufacturing processes

Stavropoulos

Papacharalampopoulos

2022

Advances in Mechanical Engineering

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Micromanufacturing raises some interesting, yet demanding and complex issues regarding modeling and data handling. Since utilizing both of these methods seems to be the key for process optimization, and preferably in real time, their coexistence is not a straightforward task, mainly due to interoperability and computational times. This work is a first step towards creating a roadmap for the design and the implementation of digital twins, provided that the digital twin offers both process optimization and tacit knowledge aggregation towards digital twin reusability. This involves the cooperation of different mathematical tools, an automated information manipulator and a human operator. Towards presenting such a roadmap and illustrating the choice of a workflow, a classification of the potentially useful tools is also presented herein. After that, a method to connect the tools through a software platform is discussed in order for a digital twin to be implemented. Finally, numerical examples are given to prove the fact that information reduction is needed in order for the proposed data manipulation effort (in terms of both processing and storing) to be minimized.

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“…(1) According to the structure characteristics of (001) crystal, suppose the [hkl] to be [hk0], then γ is equal to zero. So, the shearing modulus at any crystal orientation in (001) plane can be written as formula (3) by formula (1).…”

Section: Analysis Of Shearing Modulus On Nickel-based Single-crystal mentioning

confidence: 99%

“…However, the grinding temperature is also an important parameter for researching the grinding process. Because the micro-grinding is different from the traditional grinding [1], the fracture mechanism of nickel-based single-crystal superalloy is different from the polycrystalline material, and the grinding temperature is an important factor that affects the micro-grinding quality. During the micro-grinding process of nickel-based single-crystal superalloy, the abrasive sweep past from the workpiece surface, the abrasive not only has cutting performance but also has friction performance.…”

Section: Introductionmentioning

confidence: 99%

Study on force and temperature characteristics of micro-grinding nickel-based single-crystal superalloy

Zhou

Gong

et al. 2019

J Braz. Soc. Mech. Sci. Eng.

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Aiming at the status of fewer researches on the anisotropy of single-crystal superalloy and micro-grinding temperature field, micro-grinding using the tool of < 1 mm in diameter to remove material is the final procedure of machining micro-parts. This paper firstly analyzes the anisotropy of surface-centered cubic structural material and establishes the theoretical model of elastic modulus and shearing modulus of single-crystal superalloy in the (001), (110) and (111) crystal plane. Afterward, it builds the three-dimensional simulation model of grinding temperature based on the Hill model, adopts any Lagrangian-Euler method to realize the simulation of micro-grinding temperature, gets the distribution of temperature field and changing situation during the micro-grinding through single-factor experiment and simulation analysis, and makes a study on the laws of different grinding depths, feeding rates, grinding velocities, different crystal planes {(001), (110) and (111)} and different crystal orientations in (001) crystal plane that affect the micro-grinding temperature, thus obtaining the crystal orientation which produces low grinding force and temperature. The result indicates that the grinding temperature increases with the increase in spindle speed, feeding rate and grinding depth; the grinding force and temperature are proportional to the elastic modulus and shearing modulus of the single-crystal material; the grinding temperature along (111) crystal plane is the highest, that of the (110) crystal plane is at the middle, and that along (001) is the lowest. When grinding in the (001) crystal plane, the normal grinding force and temperature along [110], [110] , [110] , [110] crystal orientations are the highest, and those along [100], [010], [100] , [010] crystal orientations are the lowest. And along with the aggravating of wear of abrasives on the grinding tool, the normal grinding force, tangential grinding force and grinding temperature all increase and the wear state of grinding tool can be judged online according to the signal of grinding force and temperature. These results provide an important evidence to do further research on the surface integrity of grinding single-crystal superalloy.

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Modelling and optimisation of surface roughness from microgrinding of nickel-based single crystal superalloy using the response surface methodology and genetic algorithm

Cited by 28 publications

References 17 publications

Optimization of wood machining parameters in CNC routers: Taguchi orthogonal array based simulated angling algorithm

Optimization of wood machining parameters in CNC routers: Taguchi orthogonal array based simulated angling algorithm

Designing a digital twin for micromanufacturing processes

Study on force and temperature characteristics of micro-grinding nickel-based single-crystal superalloy

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