Optimization of Tungsten Heavy Alloy Cutting Parameters Based on RSM and Reinforcement Dung Beetle Algorithm

Abstract

Tungsten heavy alloys (WHAs) are an extremely hard-to-machine material extensively used in demanding applications such as missile liners, aerospace, and optical molds. However, the machining of WHAs remains a challenging task as a result of their high density and elastic stiffness which lead to the deterioration of the machined surface roughness. This paper proposes a brand-new multi-objective dung beetle algorithm. It does not take the cutting parameters (i.e., cutting speed, feed rate, and depth of cut) as the optimization objects but directly optimizes cutting forces and vibration signals monitored using a multi-sensor (i.e., dynamometer and accelerometer). The cutting parameters in the WHA turning process are analyzed through the use of the response surface method (RSM) and the improved dung beetle optimization algorithm. Experimental verification shows that the algorithm has better convergence speed and optimization ability compared with similar algorithms. The optimized forces and vibration are reduced by 9.7% and 46.47%, respectively, and the surface roughness Ra of the machined surface is reduced by 18.2%. The proposed modeling and optimization algorithms are anticipated to be powerful to provide the basis for the parameter optimization in the cutting of WHAs.

Assessing the cooling/lubricating agencies for sustainable alternatives during machining of Nimonic 80: Economic and environmental impacts

“…The increased cutting speed lowered the vibrations and reduced surface roughness while machining. A recent study reported cutting speed as a significant parameter affecting vibration and concluded that increased cutting speed reduced the vibration and surface roughness [ 3 ]. The efficient heat control under MQL and hybrid nanofluid-MQL resulted in an improved surface finish by avoiding the adhesion of workpiece material to the tool cutting edge.…”

“…A second-order polynomial regression model was developed to establish the effect of cutting speed, feed rate, and depth of cut on cutting force and vibration under dry turning. It was reported that the machining vibration was significantly affected by cutting speed, followed by feed rate and depth of cut [ 3 ]. Therefore, the researchers have employed mineral-based cutting oils for cooling and lubricating purposes in wet/flood turning to improve the machining performance [ 4 , 5 ].…”

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