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Assessment of performance parameters in intermittent turning and multi-response optimization of machining conditions using DF, MOORA, VIKOR, and coupled NSGAII-VIKOR methods

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Abstract

This study aims to assess the influence of different machining factors (Vc, f, ap, and r) during intermittent turning of cold work tool steel (AISI D3). Eight output parameters were examined, namely surface roughness (Ra), cutting force (Fz), motor power (Pm), flank wear (VB), cutting temperature (Ct), material removal rate (MRR), tangential vibration (Az), and sound intensity (Lp). A statistical study based on ANOVA was conducted to quantify the effects of cutting factors on output parameters. The results revealed that (Vc) has a predominant influence on outputs (Pm, VB, Ct, and Lp), with respective contributions of 40.37%, 66.44%, 29.72%, and 47.64%. Additionally, the factor (ap) was identified as the dominant factor for (Fz and Az), with contributions of 51.82% and 74.07%. Finally, the factor (f) is most significant for (Ra), with a contribution of 57.86%. The application of Response Surface Methodology (RSM) allowed for the development of accurate mathematical models to predict these outputs, characterized by a determination coefficient exceeding 92.28%. Ultimately, four multi-objective optimization approaches, namely DF, MOORA, VIKOR, and NSGAII coupled with VIKOR, were used to determine the optimal combination of cutting conditions. These four methods were examined and compared. The results indicate that the DF approach offers the best combination of parameters: r = 1.29 mm, Vc = 240 m/min, f = 0.1 mm/rev, and ap = 0.689 mm, leading to the minimization of six outputs (Ra, Pm, Ct, VB, Fz, and Lp) with respective values of 0.825 µm, 3282.085 Watt, 0.066 mm, 211.683 °C, 82.837 N, and 108.158 dB. On the other hand, the MOORA approach favors the minimization of vibrations (Az), with a value of 15.01 m/s2, while VIKOR presented five outputs (Pm, VB, Ct, MRR, and Lp) superior to the MOORA approach. Finally, the NSGAII approach coupled with VIKOR exhibited the best productivity value (MRR) with a rate of 405.636 mm3/s.

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Abbreviations

AISI:

American Iron and Steel Institute

ANOVA:

Analysis of variance

ap:

Depth of cut (mm)

Az:

Tangential vibration

Cont %:

Percentage contribution

Ct:

Cutting temperature

CT:

Continuous turning

CVD:

Chemical vapor deposition

DF:

Desirability function

f:

Feed rate (mm/rev)

Fz :

Tangential cutting force (N)

DIFF %:

Percentage of difference

IT:

Intermittent turning

Lp:

Sound intensity

MOORA:

Multi-Objective Optimization by Ratio Analysis

MRR:

Material removal rate (mm3/s)

NSGA II:

Non-dominated Sorting Genetic Algorithm II

Pm:

Motor power (Watt)

r:

Tool nose radius (mm)

Ra:

Arithmetic mean roughness (µm)

RSM:

Response surface methodology

VB :

Flank wear

Vc:

Cutting speed (m/min)

VIKOR:

Optimization and Compromise Solution (Vlse Kriterijumska Optimizacija Kompromisno Resenje)

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Authors and Affiliations

  1. Laboratory of Mechanics and Structure, University 8 May 1945, Guelma, Algeria

    Fethi Khelfaoui, Mohammed Athmane Yallese, Septi Boucherit, Nouredine Ouelaa & Salim Belhadi

  2. Labo MAI, National Engineering School of Tunis ENIT, University of Tunis El Manar, Tunis, Tunisia

    Sahbi Ben Salem

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  1. Fethi Khelfaoui
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All authors contributed to the study conception and design. Material preparation, data collection and analysis were performed by all authors. The first draft of the manuscript was written by KHELFAOUI Fethi and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Khelfaoui, F., Yallese, M.A., Boucherit, S. et al. Assessment of performance parameters in intermittent turning and multi-response optimization of machining conditions using DF, MOORA, VIKOR, and coupled NSGAII-VIKOR methods. Int J Adv Manuf Technol 130, 5665–5691 (2024). https://doi.org/10.1007/s00170-024-12979-0

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