International Journal of Mechanical Engineering and Technology (IJMET)

Volume 9, Issue 3, March 2018, pp. 1146–1156, Article ID: IJMET_09_03_118

Available online at http://iaeme.com/Home/issue/IJMET?Volume=9&Issue=3
ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication Scopus Indexed

A REVIEW OF MODELLING AND

OPTIMIZATION TECHNIQUES IN TURNING
PROCESSES
Sunil Kumar*, Yasir Rizvi
*Corresponding Author: Department of Mechanical Engineering,
BBDU, Lucknow, India

Raghuvir Kumar
School of management sciences Lucknow, Uttarpradesh, India

ABSTRACT
The use of modelling and optimization methods in turning process is used to
minimize the experimental runs and also to get best cutting condition. In modelling
technique a mathematical equation based model is developed based on input and
response parameter relationship to get optimum cutting condition. In optimization
technique an objective function is formulated with or without mathematical model to
get the cutting condition. Various modelling methods such as regression based
modelling; artificial neural network (ANN), fuzzy modelling and various optimization
methods such as response surface methodology (RSM), Taguchi methodology (TM)
and genetic algorithm (GA) in turning operation are discussed. Multi objective
optimization methods are also discussed in this article.
Key words: Modelling, Optimization, TM, RSM and GA
Cite this Article: Sunil Kumar, Yasir Rizvi and Raghuvir Kumar, A Review of
Modelling and Optimization Techniques in Turning Processes, International Journal
of Mechanical Engineering and Technology 9(3), 2018, pp. 1146–1156.
http://iaeme.com/Home/issue/IJMET?Volume=9&Issue=3

1. INTRODUCTION
Turning is broadly used cutting methods in manufacturing industries. The use of modelling or
optimization techniques in turning is essential tool to minimize production cost and to
improve the quality of product [1]. These techniques are focussed on founding the
relationship between responses and input cutting conditions. The optimization ofprocess
parameters gives the desired responses at lower cost [2]. The parameter optimization
technique is achieved in two stages: first an objective function is defined by mathematical
equation based on input parameter and responses; secondly the optimum cutting condition
based on input parameter and responses are determined [3].

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 A Review of Modelling and Optimization Techniques in Turning Processes

To determine optimal cutting condition mathematical models based on regression based

modelling, ANN and fuzzy modelling are used by researchers [4-10].Some optimization
techniques are also used to determine optimal responses in turning are TM, RSM and GA [11-
15].
In spite of lot of research in the field of turning using modelling and optimization
technique no one is able to find the universal model which defines input parameters and
responses for wide-ranging of cutting environments[16]. Optimization technique used in
cutting process has certain limitation and assumption and some of them are discussed in
reference [17].
In present work, a review of various existing modelling and optimization as well as multi-
objective optimization techniques used in turning process are discussed and the constraints,
assumption and shortcomings of specific techniques in turning process are also discussed.

2. MODELLING AND OPTIMIZATION TECHNIQUE

The modelling and optimization techniques classification is shown in Figure 1 and Figure 2.

Figure 1.Modelling Techniques

Figure2. Optimization Techniques

2.1. Modelling techniques

To understand the process behaviour, mathematical equation based models such as analytical
model and experimental models are mainly applied[18]. The analytical modelling approach
applied for founding the relationship between cutting inputs and responses. Due to absence of

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 Sunil Kumar, Yasir Rizvi and Raghuvir Kumar

acceptable analytical model in cutting process, experimental models are applied in machining
operation [19]. The application, usefulness and limitation of these techniques are given below.
2.1.1. Regression Based Modelling
In regression based modelling, a functional relationship between independent variables and
dependent variables are established. Regression method helps to know, how dependent
variables changes with the change of the independent variables. A regression based modelling
technique was used with N-N method to optimize surface roughness and flank wear for
turning of die steel material [20].A regression model for cutting forces as a function of speed,
feed and depth of cut (doc) is developed [21].A model between responses and speed, feed,
and doc is established[22]. A Three steps analysis has been done. In first step a second order
model in terms of speed, feed, and doc and nose radius is developed, in the second step, a
Box-Cox transformation method is applied and an improved prediction model has been
established. In final stage, conformation experiments conducted, which clearly show that the
Box-Cox transformation has a very strong technique to improve the prediction capability of
experimental models. Shows that large data set is required in regression based modelling
compared to ANN based modelling for prediction of surface roughness during turning
operation [23]. For machining of AISI 420 steel regression analysis is used to model cutting
force, tool life and surface roughness [24].Regression based modelling is used to establish the
dependency of cutting force and surface roughness on cutting parameters [25].
In regression modelling, prior assumption is required for functional relationship the
function may be linear, quadratic, polynomial or exponential. Regression technique is valid in
the region of regression variable of cutting data and not for whole universe data. For effective
use of regression model the error component of equation must have mutually perpendicular
and normally distributed with constant variance [26]. In spite of these limitations in regression
modelling is suitable for all metal cutting application.
2.1.2. Artificial neural network
ANN is a mathematical equation based model that copycats the human neurobiology in which
the data handling occurs in the form of neurons [27]. Use of ANN in turning operation is very
useful because it avoids mathematical complexity and no prior assumption is required in
functional form of relationship[28].
The common type of ANN used in literature is feed forward with some variation of back
propagation process for calculating the performance of various metal cutting processes [29-
31].ANN model is very useful in machining process for controlling surface roughness
characteristics [32]. In publication efficient optimization of the ANN has been under taken. It
was found that the best results were obtained with a low number of neurons [33].It was
established that increasing the neurons improved the overall response [34].It was established
that good results were accomplished with an optimum neurons [35].
The ANN model are generally used when regression analysis fail to provide solution. The
major problem of ANN model is that the model parameters are unpredictable for non-linear
relationship. A large set of data is required for training the data and sometime the model is
over fitted [36].
2.1.3. Fuzzy modelling
Fuzzy modelling is based on fuzzy sets, If-then rule is used for formulate the logic by creating
the statements that contain knowledge. Fuzzy modelling techniques are generally used when
objective function is constrained and decision variable is not precisely measured [37].Fuzzy
based models transform verbal problems into numerical problems [38]. Therefore, the input

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 A Review of Modelling and Optimization Techniques in Turning Processes

parameters are defined as fuzzy membership values that are derived from different
membership functions then on the basis of experimental observation [39].
There are various literatures, based on Fuzzy modelling technique available in metal
cutting. It was showed that fuzzy with ANN is required in manufacturing to control various
metal cutting problems [40]. It was predicted that the surface roughness is improved by using
fuzzy model during machining process [41].Applied a fuzzy set modelling tool based
technique on non-linear model and shows that if their exist „fuzziness‟ in the process control
variables for turning process then it more effective tool then conventional modelling
technique [42].
Fuzzy set theory has certain disadvantages also fuzzy rule is based on subjective
knowledge and opinion of expert to set the objective function. No dynamic change in cutting
process is possible [43].

2.2. Optimization Technique

The optimization of cutting parameters for differentiable and for non-differentiable objective
function is defined based on input parameters and responses and the optimal condition are
determined. Optimization techniques are classified into two groups; DOE based technique and
soft-computing methods [44].DOE based methods, such as TM, RSM these techniques
provides optimum cutting condition and whereas in soft-computing based technique an
objective function is developed to determine local optimal solution like in genetic algorithm
method[45].
2.2.1. DOE Based Technique
2.2.1.1. Taguchi methodology (TM)
It is a design and optimization technique in which experiments are performed according to
orthogonal array (OA)[46], the optimal condition is identified and a confirmation run is
conducted at optimal condition. TM changes the objective function values to signal-to-noise
(S/N) ratio to measure the performance characteristics. S/N ratio shows the quality
characteristics of the experimental data. Further Analysis of variance (ANOVA) is
accomplished to find out the importance of process parameters [47].
TM is effectively applied in number of metal cutting problems. It is showed that the
application of TM for optimization of cutting parameter in turning operation, the OA and
ANOVA is applied on AISI 1030 steel using Ti-N coated tool and experimental result shows
the effectiveness of this approach [48]. L27Taguchi OA and ANOVA is used to optimize
surface roughness [49]. Taguchi OA and ANOVA is used to optimize surface roughness and
tool life they found that TM is an efficient technique to achieve the desired response [50].
Planned and designed the experiment as per TM and found that velocity has greater effect
then feed on surface roughness [51].TM was applied to optimize cutting parameter during
hard turning with CBN tool [52].
TM has certain limitations also. This methodology is independent of intrinsic modelling
therefore greater in depth knowledge is required of the process [53]. Taguchi orthogonal array
may fail to deal interaction effects within a domain [54].
2.2.1.2. Response surface methodology (RSM)
RSM is a method in which the relationship between process parameter and response is
developed. The purpose is to measure the effects of process parameter on response and
optimization of responses [55].Firstly, the RSM is used to map the response with independent
variable. If the model is adequate then hill climbing or hill descending approach is used for

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 Sunil Kumar, Yasir Rizvi and Raghuvir Kumar

maximization or minimization of the problem and same mapping technique is repeated. At the
locality of optimal point, second order model are generally found good[56].
The RSM is used in various metal cutting problems by different researchers. To check the
surface roughness using RSM, it was found that effect of feed on surface roughness is more
comparing to speed and doc [57]. The finding shows which machining parameters have to be
used for different combination of cutting tool workpiece material for achievement of desired
surface finish [58].The construction of first and second order RSM model along with contour
plot to increase the MRR and improve surface quality [59]. RSM model improve the surface
roughness under dry cutting condition [60]. There was a use of central composite design
(CCD) in RSM to predict surface roughness and thrust force during turning of titanium alloy
[61]. There was use of Box-Behnken design (BBD) in RSM to model and optimize residual
stress while machining die-steel [62].A full factorial design was used to analyse experimental
result via ANOVA and RSM [63]. The results indicate that the doc was dominant factor
affecting force, while feed rate is found to be utmost factor influencing surface roughness
behaviour. RSM method find out the effect of cutting parameter on surface roughness and
cutting force for the case of turning of AISI 52100 bearing hardened steel 64 HRC with CBN
tool [64].
RSM model has certain limitation also. RSM model can work for maximum three
responses. RSM for more than three outputs gives undefined saddle function in second order
response surface model. Sometimes RSM model is not cost effective due to series of
experimentation for many manufacturing situations [65].
2.2.2. Meta-Heuristic Search
Heuristic, generally provide most acceptable solution out of all available solution at
reasonable computational cost. Meta-Heuristic approach helps and modifies other heuristic to
produce optimal solution which normally generated from local optimality. The meta-heuristic
based algorithm such as GA is generally used by researcher for optimization of cutting
parameters in metal cutting.
2.2.2.1. Genetic algorithm (GA)
GA is a search algorithm method in which optimization is based on evolution theory. This
technique provides a solution space compassing of high proportion of good solution. The GA
involves three steps that is selection, cross-over and mutation which create new generation
from initial population [66].The procedure continues by considering current population as
initial population up-to the termination criteria. The GA is preferred for complex cutting
parameter optimization problem.GA is very efficient for single as well as multi optimization
technique, some of the advantages of GA are as it is independent of gradient-based
information, the search space of GA is large and search direction is probabilistic type
therefore chance of local optimal solution is less. GA has ability to solve multi-model
function, multi objectives non-linear discreet and continuous functional problems [67].
The GA based technique in metal cutting problems by many researchers. The application
of GA is very useful method of obtaining process parameters in order to get the required
surface finish [68]. For multi-pass turning with multi-objectives GA based technique is very
useful to get near optimal solution [69].It was showed that the modelling of N-N technique
with GA to optimize cutting condition shows that MRR is improved with this technique
[70].GA optimization technique is used in turning of steel to determine optimal cutting
condition and to minimize production cost [71]. Optimization pattern based on GA is used to
decide optimal cutting parameter during turning operation [72].

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 A Review of Modelling and Optimization Techniques in Turning Processes

GA model has certain limitation also. GA is required to merge with some neural network
technique to get optimize cutting condition. There exists no rule for selection of algorithm
such as population size number of generation required for evaluation, crossover probability. It
also required substantial time to attain near-optimal solution.

3. MULTI-OBJECTIVE OPTIMIZATION
To optimize more than one response parameter multi-optimization techniques are used
because single optimization technique is not able to provide appropriate solution [73].
Research based on multi-optimization techniques are generally, Taguchi based grey relational
analysis (TGRA), RSM with TM, ANN with regression technique, ANN with GA.
The TGRA can effectively solve multi-response characteristic problem. TGRA a grey
relational grade (GRG) is obtained to evaluate multiple performances characteristic [74]. The
obtained GRG is converted into single GRG. Application of TGRA on turning operation
improved the performance characteristics of surface roughness, tool life and cutting force
simultaneously [75].MOO was used to minimize cutting force, surface roughness and flank
wear using high speed dry turning of Inconel-718, result shows that optimal process
parameters are 60 m/ min cutting speed, 0.05mm/rev for feed and 0.2mm for doc [76].TGRA
based MOO was used to optimize cutting edge geometry during high speed turning of
Inconel-718 [77].TM (L27 orthogonal array) combined with RSM using MOO, further
ANOVA is used to model the surface roughness (Ra and Rz), under dry condition [78].TM
and RSM based MOO technique was used to optimize cutting force and surface roughness
while machining AISI H13 steel [79]. Regression and ANN based MOO technique to predict
the minimum surface roughness of real experimental data [80]. TM and ANN based MOO
technique was used to predict performance parameter during CNC turning [81].RSM and
fuzzy interface system was used for MOO to optimize surface roughness, the model selected
for optimization is validated by F-test and adequacy of the models on surface roughness had
been established with ANOVA [82]. A full factorial design and ANN with RSM based MOO
technique to evaluate the performance of machining parameters during turning if die-steel
with ceramic tool [83].TM and fuzzy logic reasoning was usedfor MOO high speed CNC
turning of AISI P-20 tool steel using Ti-N coated tungsten carbide coating [84].

4. SUMMARY
The ANN and fuzzy modelling are based on network architecture and generally used when
input and response parameter model is non-linear, it is superior technique when objective
function is conflicting and decision variable is not completely defined. Linear regression
technique is also a modelling technique and it is generally used when the function is linear,
quadratic or exponential.TM and RSM are DOE based technique and it is suitable for both
continuous and discreet responses. GA based optimization techniques suitable for multi-
model non-linear response function.

5. CONCLUSIONS
In present work, different approaches of modelling and optimization techniques as well as
multi optimization techniques their applications, advantages and limitations of different
technique as well as potential area of improvement were discussed.

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 Sunil Kumar, Yasir Rizvi and Raghuvir Kumar

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