Neural network process modelling for turning of steel parts using conventional and wiper Inserts

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1 Neural network process modelling for turning of steel parts using conventional and wiper Inserts Tugrul Özel* Department of Industrial and Systems Engineering, Rutgers University, Piscataway, NJ , U.S.A. *Corresponding author A. Esteves Correia Department of Mechanical Engineering and Industrial Management- DEMGI, School of Technology, Polytechnical Institute of Viseu, Campus de Repeses, 4-50 Viseu, Portugal J. Paulo Davim Department of Mechanical Engineering, University of Aveiro, Campus Santiago, Aveiro, Portugal Abstract: In this paper, the effects of tool corner design on the surface finish and productivity in turning of steel parts are presented. Surface finishing and has been investigated in finish turning of AISI 045 steel using conventional and wiper (multi-radii) design inserts. Multiple linear regression models and neural network models are developed for predicting surface roughness, mean force and cutting power. Experimental results indicate that lower surface roughness values are attainable with wiper tools. Neural network based predictions of surface roughness are carried out and compared with a nontraining experimental data. These results show that neural network models are suitable to predict surface roughness patterns for a range of cutting conditions in turning with conventional and wiper inserts. Keywords: regression models, wiper inserts, neural network models, turning, surface roughness, cutting forces.

2 Introduction In most turning applications, conventional inserts are used. Conventional inserts have a corner radius along with a proper edge preparation that is often a chamfered and/or honed which has profound effects on surface roughness (Özel et al., 005). To improve the overall efficiency, a multi-radii (wiper) design on the corner of the inserts is introduced (see Figure. In essence, a wiper design tool increases feed rate twice while maintaining same surface roughness compared to a corner radius tool which is referred as high feed rate turning (Boothroyd and Knight, 006). Recently, high feed rate machining without sacrificing from surface roughness become an important development with the introduction of wiper geometry inserts. The essence in turning with multi-radii wiper tools is to give insert a more flat surface on the secondary cutting edge and wipe the scallops that are typical forms in inserts with a simple corner radius. Bar turning with wiper inserts provides improved surface roughness or increases the feed rates by a factor of two; hence, results in either better surface finish or higher productivity in machining applications (Boothroyd and Knight, 006). However, the influence of wiper inserts on machining performance is still not well understood. Figure Wiper insert design: r ε and r ε are radii of wiper curvature f a p r ε Ra i r ε In a recent study, Grezik and Wanat (005) presented experimental results for machining AISI 540 (DIN 4Cr4) workpiece with a hardness of 60 ± HRC using both conventional corner radius and multi-point radius (wiper) geometry mixed alumina (Al O 3 )-titanium carbide (TiC) ceramic inserts. Lima et al. (005) presented results for hard turning of AISI D tool steel (58 HRC) using mixed-alumina ceramic inserts with conventional corner radius geometry and reported that surface finishes as good as that produced by cylindrical grinding were attainable. Recently, Davim and Figueira (007) investigated the machinability of AISI D tool steel using experimental and statistical techniques. The influence of machining parameters (cutting velocity and feed) under flank wear, specific cutting force and surface roughness on machinability evaluation in hard turning with ceramic tools using analysis of variance (ANOVA) is presented.

3 In this study, machining of AISI 045 steel workpieces using multi-radii wiper tungsten carbide was investigated and process models for predicting specific forces and surface roughness were developed. Experimental procedure and process models. Experimental Procedure The main objective of this experimental work was to investigate the influence of insert geometry both conventional and wiper (multi-point radius) corner geometry on forces and surface quality in turning of AISI 045 steel. Turning experiments were performed using a high rigidly CNC lathe (KINGSBURY 50 with Fanuc control) with 8kW spindle power and a maximum spindle speed of 4 rpm. The following cutting parameters were used: cutting speed (V c ) of 345, 40, 470 m/min, feed rates (f) of and 5mm/rev and constant depth of cut (a p ) of mm. The experiments had been carried out in workpieces pre prepared with approximately 50 mm of diameter and length 0 mm, with tracks of 8 mm as shown in Figure. During longitudinal turning, the tracks provide 8 mm axial length of cut with 6 mm gap interruptions. The schematic representation of longitudinal interrupted turning is given in Figure 3. Figure Workpiece specimen used in the tests (all units are in mm) 35 R Figure 3 Schematic diagram of longitudinal interrupted turning TOP VIEW Depth of cut,a p FRONT VIEW Workpiece Tool Major cutting edge r ε X Z r ε Y Z Feed direction

4 Conventional cemented carbide inserts (CNMG 0404 PF, CNMG 0408 PF) and wiper cemented carbide inserts (CNMG 0404 WF, CNMG 0408 WF) (Figure ) were used in machining of AISI 045 steel bars. The geometry and the dimensional specifications of the inserts are given in Figure 4 and Table. Type PCLNL 0 0 K (ISO) tool holder has provided the following geometry: -6º rake angle, 0º clearance angle, 95º edge major tool cutting, point angle 80º, and -7º cutting edge inclination angle.. The bar workpieces were held in the machine with a collet to minimize run-out and to maximize rigidity. Figure 4 Insert geometry for conventional (PF) and wiper (WF) inserts Table Specifications of the conventional (PF) and wiper (WF) inserts. Parameter CNMG PF 55 CNMG WF 55 CNMG PF 55 CNMG WF 55 l s ic r ε The acquisition of the cutting forces was performed by a piezoelectric dynamometer. The values were continuously monitored and recorded through out the test by using a charge amplifier of the three channels with data acquisition capability. The surface roughness was evaluated (according to ISO 487/) with a Hommeltester T000 profilometer. For each measurement over turning surfaces, two replications were performed. A three factor two or three level factorial design was used to determine the effects of corner radius, cutting speed, feed rate on resultant forces and surface roughness. The factors and factor levels are summarized in Table. These factor levels results in a total of 36 (3fx3V c xr ε xtools) unique factor level combinations. The response variables are the workpiece surface roughness, R a, the mean force, F m, and specific force respectively.

5 Table Factors and factor levels Factor Factor levels Insert corner radius, r ε and (mm) Cutting speed, V c Feed rate, f Insert type 345, 40, 470 (m/min) 0.075,, 5 (mm/rev) PF and WF. Neural network based process models Many researchers utilized neural network modeling of turning process in order to predict surface roughness, tool life and other machining parameters. In an earlier work, Azouzi and Guillot (997) examined the feasibility of neural network based sensor fusion technique to estimate the surface roughness and dimensional deviations during machining. This study concluded that depth of cut, feed rate, radial and z-axis cutting forces are the required information that should be fed into neural network models to predict the surface roughness successfully. In addition to those parameters, Risbood et al. (003) added the radial vibrations of the tool holder as additional parameter to predict the surface roughness. During their experiments they observed that surface finish first improves with increasing feed but later it starts to deteriorate with further increase of feed. Benardos and Vosniakos (003) made an extensive literature review on predicting surface roughness in machining and confirmed the effectiveness of neural network approaches. Feng and Wang (003) compared regression models with a feed-forward neural network model by using sparse experimental data obtained for traditional turning. Their results indicated that backpropagation neural network modeling provided better predictions for all of the cutting conditions that they are trained for. However, the authors concluded that regression models might perform better when experimental data generated from experimental design. Özel and Karpat (005) presented results for predicting surface roughness and tool wear using both regression analysis and neural network models in finish hard turning. They demonstrated that the neural network modelling can predict the surface roughness patterns during hart turning. Karpat and Özel (005) presented swarm intelligent neural networks for selecting machining parameters for optimum surface finish, tool wear and machining time. Neural networks are nonlinear mapping systems consisting of neurons and weighted connection links, which consist of user-defined inputs and produce an output that reflects the information stored in connections during training. A multilayer neural network consists of at least three layers: input, hidden and output layer where inputs, p i, applied at the input layer and outputs, a i, are obtained at the output layer and learning is achieved when the associations between a specified set of input-output (target) pairs {( p, t ), ( p, t), L, ( p, Q t Q) } are established as illustrated in Figure 5. Learning or training as often referred is achieved by minimizing the sum of square error between the predicted output of the neural network and the actual output over a number of available training data, by continuously adjusting and finally determining the weights connecting neurons in adjacent layers.

6 .. Back-propagation algorithm Backpropagation is the most commonly used training method where the weights are adjusted according to the calculated error term using steepest descent method. The backpropagation training methodology can be summarized as follows. Consider the multilayer feed-forward neural network given in Figure 5. The net input to unit i in layer k+ is: k S k + k k k i = + i, j j + + i j= n w a b () The output of unit i will be a = f ( n ) () k+ k+ k+ i i where f is the activation function of neurons in (k+)th layer. The performance index, which indicates all the aspects of this complex system, is selected as mean squared error. Q Q T M M T V = ( tq aq ) ( tq aq ) = eqe (3) q q= q= M In Equation 3, a q is the output of the network corresponding to q th input p Q, and M e q = ( tq a q ) is the error term. In backpropagation learning, weight update can be performed either after the presentation of all training data (batch training) or after each input-output pair (sequential training). The weight update for the steepest descent algorithm is k V wi, j = α (4) w k i, j k V bi = α (5) k bi where α is the learning rate, which should be selected small enough for true approximation and also at the same time large enough to speed up convergence. Gradient terms in Equations (4) and (5) can be computed by utilizing the chain rule of differentiation. Effects of changes in the net input of neuron i in layer k to the performance index are defined as the sensitivity shown with Equation 6. k V δ i (6) n k i The backpropagation algorithm proceeds as follows; first, inputs are presented to the network and errors are calculated, second, sensitivities are propagated from the output layer to the first layer, then, weights and biases are updated using Equations (3) and (4). In this study, the Levenberg-Marquardt method is used together with Bayesian regularization in training neural networks in order to obtain neural networks with good generalization capability. The basic assumption in Bayesian regularization is that the true underliyng function between input-output pairs should be smooth and this smoothness

7 can be obtained by keeping network weights small and well distributed within the neural network. This is achived by constraining the size of the network weights which is referred to as regularization which adds additional terms to the objective function F = βv + αw (7) where V is the sum of squared errors (performance index) which defined in Eq. 3, W is the sum of squares of the network weights, α and β are objective function parameters. This modification in performance index will result in a neural network with smaller weights and biases which will force its response to be smoother and decrease the probability of overfitting. Training with Bayesian regularization yields important parameters such as sum of square errors (SSE), sum of squares of weights (SSW) and number of effective parameters used in neural network, which can be used to reduce guesswork in selection of number of neurons in hidden layer (Özel and Karpat, 005). In addition, the non-linear tanh activation functions are used in the hidden layer and input data are normalized in the range of [-, ]. Linear activation functions are used in the output layer. The weights and biases of the network are initialized to small random values to avoid immediate saturation in the activation functions. The data set is divided into two sets as training and test sets. Neural networks are trained by using training data set and their generalization capacity is examined by using test sets. The training data never used in test data. Matlab s neural network toolbox is used to train neural networks. Specifically the Matlab functions such as train, newff and trainbr are used for training a feed-forward backpropagation network with Bayesian regularization. Simulations with test data repeated many times with different weight and bias initializations. Figure 5 Multilayer feed-forward neural network w, p w, b w, p b O b a b 3 O a output layer b p q input layer b n hidden layer

8 3 Results and discussions 3. Experimental results and process models The measured force components are represented with a mean machining force, F m, which is resultant of three force components: main cutting force F c, feed force F f and thrust force F t, as give in Equation (8). Fm = Fc + Ff + Ft (8) Cutting power, P c, and specific cutting force, K s, are also calculated. Surface roughness R a are given in Table 3. Using the data presented in Table 3, a multiple linear regression model that correlates R a values to the machining parameters can be obtained with maximum error of 0933 for R a, 3577 for F m and for P c respectively as given in Equations (9), (0) and () c Ra = V f r ε (9) c Fm = 363V f r ε (0) c Pc = V f r ε () These models can be utilized in process planning for finish turning of AISI 045 steel using conventional and wiper inserts. As it can be seen from the maximum error value, surface roughness prediction is not suitable with such models. Therefore, neural network modelling is proposed for predicting surface roughness generation when turning with those inserts. However, prediction of mean forces and power using wiper tools can be made with a reasonable confidence using these models as shown in Figure 6.

9 Table 3 Experimental results (F t, thrust force; F f, feed force and F c, cutting force. P c = F c V c, where V c is cutting velocity. K s = F c S, where S is a p f) Insert Type Factors r ε [mm] f [mm/rev] V c [m/min] F m [N] R a [µm] P c [kw] K s [KN/mm ] PF PF WF WF

10 Figure 6 Comparison of actual (+) and fitted (o) data using a multiple linear regression model Power [kw] Number of Cutting Conditions Mean Force, Fm [N] Number of Cutting Conditions 3. Modelling of surface roughness with neural networks In this study, surface roughness is modelled with a feed-forward multilayer neural network as shown in Figure 7. Cutting speed, feed rate, corner radius, mean machining force, cutting power, and specific force are used as inputs to neural network. This neural network is trained with 8 data points (cutting conditions). It is tested on 8 data points (cutting conditions) which are randomly chosen from different cutting conditions. Training procedure for selecting number of neurons in hidden layer and associated rms erros are given in Table. Neural network structure 3-5- is found to be sufficient for training using surface roughness, R a data set. Neural network model for surface roughness for given the PF conventional insert training data sets used has rms error around 75 where as the neural network model for surface roughness for the WF wiper insert has rms error of Figure 7 Architecture of multilayer feed-forward neural network used for predictions Input layer Hidden layer Output layer Vc f F m or R a rε

11 .5 Figure 8 Predicted surface roughness using neural network models: (a) conventional inserts (b) wiper inserts Surface Roughness, Ra, microns predicted re= mm f= mm/rev measured re= mm f= mm/rev predicted re= mm f= mm/rev measured re= mm f= mm/rev Cutting speed, m/min Surface Roughness, Ra, microns predicted re= mm f= mm/rev measured re= mm f= mm/rev predicted re= mm f= mm/rev measured re= mm f= mm/rev Cutting speed, m/min 3. Effect of feed rate and cutting speed on surface roughness Feed rate is known to affect surface finish in turning with corner radius inserts. This is also valid for multi-radii wiper inserts to a lesser extend. The influence of feed rate on surface roughness is less when compared to conventional corner radius inserts according to Grzesik and Wanat (006), Davim and Figueira (007) and T. Özel et al. (006). Figures 9 and 0 illustrates the effects of feed rate and cutting speed parameters on the surface roughness, R a for the conventional and the wiper inserts with and mm corner radius respectively. Figure 9 Comparison of surface roughness generated with conventional and wiper inserts (r ε = mm) Ra [microns] CNMG0404PF Ra [microns] CNMG0404WF

12 Figure 0 Comparison of surface roughness generated with conventional and wiper inserts (r ε = mm) Ra [microns] CNMG0408PF Ra [microns] CNMG0408WF Effect of feed rate and cutting speed on mean force Cutting forces, and power are related to the productivity and cost-effectiveness of the finish hard turning process, hence, they are also investigated. Figures and illustrates the effects of feed rate and cutting speed parameters on the mean force, F m for the conventional and the wiper inserts with and mm corner radius respectively. Figure Comparison of mean forces generated with conventional and wiper inserts (r ε = mm) Mean Force [N] CNMG0404PF Mean Force [N] CNMG0404WF

13 Figure Comparison of mean forces generated with conventional and wiper inserts (r ε = mm) Mean Force [N] CNMG0408PF Mean Force[N] CNMG0408WF Conclusions In this study, surface finishing has been investigated in turning of AISI 045 steel using conventional and wiper (multi-radii) design inserts. Multiple linear regression models and neural network models are developed for predicting surface roughness. The following conclusions are drawn form the study: The premise of using multi-radii wiper tools to higher feed rates while maintaining good surfaces finishes has been realized. Experimental results indicate that surface roughness Ra values as low as 6 µm with mm corner radius and µm with corner radius are attainable with wiper tools. In general, low feed rates provided better tool life, and better surface finishes were obtained at the lowest feed rate and highest cutting speed combination. Neural network based predictions of surface roughness are carried out and compared with a non-training experimental data. These results show that neural network models are suitable to predict surface roughness patterns for a range of cutting conditions and can be utilized in intelligent process planning for turning with wiper tools. References Azouzi, R. and Guillot, M. (997) On-line prediction of surface finish and dimensional deviation in turning using neural network based sensor fusion, International Journal of Machine Tools and Manufacture, Vol. 37, No. 9, pp 0-7. Benardos, P.G. and Vosniakos, G.C. (003) Predicting Surface Roughness in Machining: A Review, International Journal of Machine Tools and Manufacture, Vol. 43, pp Boothroyd G., Knight W. A., Fundamentals of Machining and Machine Tools, Third Edition, CRC Press, 006. Davim J. P. and Figueira L. (007) Machinability evaluation in hard turning of cold work tool steel (D) with ceramic tools using statistical techniques Journal of Materials and Design, Vol. 38 (4), Feng, C.X. and Wang, X.F. (003) Surface roughness predictive modeling: neural networks versus regression, IIE Transactions, Vol. 35, pp. -7.

14 Grzesik, W. and Wanat, T. (006) Surface finish generated in hard turning of quenched alloy steel parts using conventional and wiper ceramic inserts, International Journal Machine Tools and Manufacture, Vol. 46 (5), pp Grzesik, W., Wanat, T. (005) Hard turning of quenched alloy steel parts using conventional and wiper ceramic inserts, Transactions of NAMRI/SME, Vol.33, 005, pp Karpat, Y. and Özel, T. (005) Hard turning optimization using neural network modeling and swarm intelligence, Transactions of NAMRI/SME, Vol. XXXIII, pp Karpat, Y. and Özel, T. (006a) Swarm-Intelligent Neural Network System (SINNS) based multiobjective optimization of hard turning, Transactions of NAMRI/SME, Vol. XXXIV, pp Karpat, Y. and Özel, T., (006b) "Multi-Objective optimization for turning processes using neural network modeling and dynamic-neighborhood particle swarm optimization," International Journal of Advanced Manufacturing Technology, DOI 0.007/s (in print). Lima, J. G, Avila, R.F., Abrao, A. M., Faustino, M. and Davim, J. P. (005) Hard turning: AISI 4340 high strength low alloy steel and AISI D cold work tool steel, Journal of Materials Processing Technology, Vol. 69, Özel, T., and Karpat, Y. (005) Predictive modeling of surface roughness and tool wear in hard turning using regression and neural networks, International Journal of Machine Tools and Manufacture, Vol. 45, pp Özel, T., Hsu, T-K. and Zeren, E. (005) "Effects of cutting edge geometry, workpiece hardness, feed rate and cutting speed on surface roughness and forces in finish turning of hardened AISI H3 steel", International Journal of Advanced Manufacturing Technology, Vol. 5, pp Özel, T., Karpat, Y., Figueira, L., and Davim, J. P. (006) "Prediction of surface finish and tool wear with neural network modelling in hard turning of AISI D steel using ceramic wiper inserts," Journal of Materials Processing Technology, (submitted). Risbood, K.A., Dixit, U.S. and Sahasrabudhe, A.D. (003) Prediction of surface roughness and dimensional deviation by measuring cutting forces and vibrations in turning process Journal of Materials Processing Tech., Vol. 3, pp

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