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Articial neural networks (ANNs) models were developed for the analysis and prediction of
the relationship between the cutting conditions and the corresponding fractal parameters
of machined surfaces in face milling operation. These models can help manufacturers to
19 August 2007
determine the appropriate cutting conditions, in order to achieve specic surface rough-
ness prole geometry, and hence achieve the desired tribological performance (e.g. friction
and wear) between the contacting surfaces. The input parameters of the ANNs models are
the cutting parameters: rotational speed, feed, depth of cut, pre-tool ank wear and vibra-
Keywords:
tion level. The output parameters of the model are the corresponding calculated fractal
parameters: fractal dimension D and vertical scaling parameter G. The model consists
Neural network
successfully for modeling and predicting the fractal parameters D and G in face milling
Milling operation
operations. Moreover, WM fractal function was integrated with the developed ANNs models
Speed
Feed
The predicted proles were found statistically similar to the actual measured proles of test
Depth of cut
specimens.
2007 Elsevier B.V. All rights reserved.
1.
Introduction
Corresponding author.
E-mail address: khashabu@zu.edu.eg (U.A. Khashaba).
0924-0136/$ see front matter 2007 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2007.09.006
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2.
Fractal geometry
log N
log m
(1)
2.1.
Fractal characterization of surface roughness
proles
The proles of machined surfaces appear random, multi-scale,
and disordered. The mathematical properties of such proles are continuous everywhere but non-differentiable at all
points. Such proles are also known to be self-afne in roughness structure (Zhu et al., 2003). In addition, it was found that
the WM fractal function satises these properties of continuity, non-differentiability, and self-afnity. Therefore the WM
fractal function can be used to characterize and simulate such
proles (Majumdar and Bhushan, 1990; Majumdar and Tien,
1990). The modied WM function is given by:
max
G D1 n
cos(2 n x/L)
z(x) = L
n=0
(2D)n
(2)
where G is the vertical scaling parameter, D the fractal dimension (1 < D < 2), L the sample length of measured prole, x the
coordinates of x-axis for the measured sample length, is chosen to be equal to 1.5 providing both the phase randomization
273
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S() =
S() =
1
L
[z(xss + ) z(x)] dx
(3)
1
(N )/x
[z(xi + ) z(xi )]
(4)
i=1
Wt (%)
C
Mn
Cr
S
Mo
Cu
0.07216
1.02
0.045
0.2798
0.0235
0.02935
(5)
Experimental work
3.1.
Element
(N)/x
3.
560
900
1400
Feed rate
(mm/min)
Depth of cut
(mm)
11.2
18
28
0.5
0.75
The total number of machined specimens was 41 specimens. They were divided into two groups; the rst group was
consisting of 36 specimens (that used as the training and
validation sets for developing the ANNs). The second group
was consisting of ve specimens (that used to test the performance of the trained ANNs models). The machining trials
that were employed for producing the rst and second groups
are illustrated in Tables 2 and 3, respectively. The machining
operations, which indicated in Table 2, were repeated with
different pre-machining tool wear to investigate how the tool
wears affecting the nal product surface quality. Before conducting the machining trials, up to 3 mm thickness of the
top surface of each specimen was cleaned in order to eliminate any skin defects that can adversely affect the machining
results. During the machining operations, cutting forces are
exerted on the cutting tool tips, which in turn, cause vibration during the machining process. Thus for each machining
operation the vibration level was determined by using an integration vibration meter, type 2513. The observed values of
vibration level are used as one of the patterns input signal
to train the developed ANNs models. Furthermore, since the
tool wear inuences the quality of the machined surfaces, the
dimensional accuracy, and consequently the economics of the
cutting operations, the cutting edge ank wear of inserted tips
were measured for each machining condition, and used as one
of the patterns input signal to train the ANNs models. The
measurements of tool ank wear were implemented by using
an optical microscope of type 2158 with a venire resolution of
0.01 mm.
Speed (rpm)
450
710
1120
1400
1800
Feed rate
(mm/min)
35.5
35.5
14
45
22.4
Depth of
cut (mm)
0.8
0.5
0.5
0.75
0.35
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Fig. 3 The structure of ANN model for prediction of fractal parameters D and G.
3.2.
All the machined surfaces were characterized by measuring the roughness proles at different six positions over
each machined surface, which gives 216 total measurements.
The measurements were carried out using Taylor Hobson
Surtronic 3+ surface roughness measuring instrument, taking a traversing length of 4.0 mm and a cut-off length of
0.8 mm.
The roughness prole was acquired in a data le through
personal computer (every micron is represented by two data
points) that connected with the roughness instrument. This
could be performed by using the surface analysis software
program ST3PL.EXE which associated with the measuring
instrument. The fractal parameters D and G were calculated and used as the output patterns to train the developed
ANNs models.
4.
4.1.
Prediction of fractal parameters using ANNs
models
A neural network is a massively parallel-distributed processor made up of simple processing units, which have a natural
propensity for storing experimental knowledge and making it available for use. Modeling the manufacturing process
using the ANN model could be denoted as system identication problem, where the set of actual experiments, which
applied on the machine tool (unknown system), can be utilized as training examples for training and developing ANN
model. The difference between the actual output of manufacturing process and the corresponding response of the
ANN model provides an error signal. This error signal in
turn is used in adjusting the free parameters of the neural
network to minimize the squared difference between the output of the unknown system and the neural network (Haykin,
1999).
The networks are selected to be feed-forward backpropagation neural networks. The networks consist of three
layers: the input, hidden and output layer. The input layer
consists of ve input nodes, and the output layer has only
Table 4 The different structures of ANNs models for prediction the fractal parameters D and G
6.33a
5-5-1
5-5-1
5-5-1
2.33
2.55
2.27
1.34
1.73
1.59
2.24
1.98
2.19
1.38
1.60
1.93
2.19
1.98
2.00
2.21
0.91
3.06
1.97a
7.02
9.71
7.12
7.68
3.41
8.54
5.91
6.09
7.96
4.15
7.17
6.17
8.00
3.72
4.99
5.93
6.34
4.10
5-10-1
5-10-1
5-10-1
2.68
2.58
3.17
1.43
1.43
1.29
3.15
3.87
2.64
1.18
1.54
1.80
1.66
3.01
2.04
0.82
2.72
2.12
2.18
7.31
11.08
7.92
6.54
10.90
8.07
8.56
11.46
6.22
7.27
8.75
8.55
7.38
7.13
8.67
10.03
4.87
10.45
8.4
5-15-1
5-15-1
5-15-1
2.64
2.13
2.32
3.04
2.63
2.29
2.88
2.35
3.32
1.87
2.14
3.38
2.40
1.65
3.05
1.77
2.27
2.67
2.15
6.44
11.07
10.64
7.90
10.98
10.94
10.90
11.45
5.69
9.77
12.66
11.72
9.64
11.16
5.99
13.39
4.84
5.71
9.5
5-20-1
5-20-1
5-20-1
2.75
3.48
2.95
2.39
3.59
2.26
3.96
2.97
3.87
2.23
2.01
1.94
3.27
1.69
2.30
2.68
2.26
4.95
2.87
12.16
8.13
11.36
13.18
6.81
10.40
6.94
10.46
9.59
12.77
12.91
10.14
6.01
11.23
7.54
8.34
12.89
11.64
10.14
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4.2.
Performance assessment of the developed ANNs
models
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Mean
value (%)
Average values of APE at six different
positions for vertical scaling parameter (G)
Mean
value (%)
Average values of APE at six different
positions for fractal dimension (D)
Structure of
ANNs models
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Fig. 6 Performance of trained ANNs models, using regression analysis for prediction of (a) fractal parameter D, (b) fractal
parameter G.
Fig. 7 Comparison between the actual and predicted proles for (a) specimen no. 1, (b) specimen no. 2.
j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 0 ( 2 0 0 8 ) 271278
4.3.
5.
Conclusions
In this work, the articial neural networks (ANNs) technique was utilized for the prediction of fractal parameters
D and G. The predicted fractal parameters were used in
the WM fractal function in order to generate an articially
fractal predicted proles. These models can help manufacturers to determine the appropriate cutting conditions, in
order to achieve specic surface roughness prole geometry, and hence achieve the desired tribological performance
(e.g. friction and wear) between the contacting surfaces. Several attempts were made to reach the best structure of
these networks. The obtained results can be listed as the
following:
277
3. The performance of developed ANNs models, were statistically demonstrated by applying the following techniques:
rst, ANOVA technique which gave p-values of 0.76 and
0.98. Secondly, the regression analysis method which
resulted in the correlation coefcients R of 0.895 and 0.925
for prediction of fractal parameters D and G, respectively.
4. The trained ANNs models for prediction of fractal parameters D and G was integrated with the WM fractal
prole simulation function, in order to predict the surface roughness proles of corresponding applied cutting
conditions. The predicted proles were found to be statistically similar to the actual measured proles, based
on the plotted probability density functions. Moreover,
the predicted proles exhibited more details than the
actual measured roughness proles, so that they could
be used effectively for establishing different contact
models.
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