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Multi-objective optimization of MQL system parameters for the roller burnishing operation for energy saving, product quality and air pollution

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Abstract

Internal burnishing operation is a prominent solution to improve the hole quality. In this study, minimum quantity lubrication (MQL) system parameters, including the diameter of the nozzle (N), impingement angle (I), the pressure of the compressed air (P), the flow rate of the lubricant (L), and the distance between the nozzle and workpiece (D) are optimized for decreasing the total energy consumption (TE), average surface roughness (AR), and air quality indicator (AI) of the internal roller burnishing process. The predictive models of performance measures were developed using the adaptive neuro-based-fuzzy inference system (ANFIS) approach, while a novel model is developed to compute the total burnishing cost (BC). The neighborhood cultivation genetic algorithm (NCGA) and the VIKOR method were used to generate a set of prominent solutions and determine the best selection. The outcomes presented that the optimizing values of the N, I, P, L, and D are 1.0 mm, 35 deg., 0.3 MPa, 70 ml/h, and 10 mm, respectively. The TE, AI, AR, and BC are decreased by 3.1, 9.3, 20.6, and 7.9%, respectively, at the chosen point. The proposed performance measures could be utilized to precisely forecast the responses in the practical burnishing. The developed optimizing method combining the ANFIS, NCGA, and VIKOR could be effectively utilized to deal with complicated optimization issues for machining operations. The observed findings provided efficient information, which could help machine operators to select the optimal MQL system parameters and enhance the burnishing performances.

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of laborers serving burnishing operations.

Abbreviations

AI:

Air quality indicator (µg/m3)

AR:

Average surface roughness (µm)

BC:

Burnishing cost (USD)

BD:

Burnishing depth (mm)

BS:

Burnishing speed (m/min)

D:

Distance between the nozzle and workpiece (mm)

FR:

Feed rate (mm/rev)

I:

Impingement angle (deg)

L:

Flow rate of the lubricant (ml/h)

MQL:

Minimum quantity lubrication

N:

Diameter of the nozzle (mm)

P:

Pressure of the compressed air (MPa)

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Authors and Affiliations

  1. Faculty of Engineering and Technology, Nguyen Tat Thanh University, 300A Nguyen Tat Thanh Street, Ward 13, District 4, Ho Chi Minh City, 70000, Vietnam

    An-Le Van

  2. Faculty of Mechanical Engineering, Le Quy Don Technical University, 236 Hoang Quoc Viet, Ha Noi, 100000, Vietnam

    Trung-Thanh Nguyen

  3. Department of Automatic Control, Ho Chi Minh City University of Technology and Education, No. 1 Vo Van Ngan Street, Linh Chieu Ward, Thu Duc City, Ho Chi Minh City, 70000, Vietnam

    Xuan-Ba Dang

  4. Hanoi University of Industry, No. 298, Cau Dien Street, Bac Tu Liem District, Ha Noi, 1000, Vietnam

    Phan-Nguyen Huu

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  1. An-Le Van
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  2. Trung-Thanh Nguyen
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  4. Phan-Nguyen Huu
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Correspondence to Trung-Thanh Nguyen.

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Van, AL., Nguyen, TT., Dang, XB. et al. Multi-objective optimization of MQL system parameters for the roller burnishing operation for energy saving, product quality and air pollution. Soft Comput 28, 1229–1254 (2024). https://doi.org/10.1007/s00500-023-09165-x

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