Expert Systems with Applications 36 (2009) 96459657

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Expert Systems with Applications

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Modelling of the cutting tool stresses in machining of Inconel 718 using articial neural networks
Abdullah Kurt *
Gazi University, Technical Education Faculty, Mechanical Education Department, Teknikokullar, 06500 Ankara, Turkey

a r t i c l e

i n f o

a b s t r a c t
This study covers two main subjects: (i) The experimental and theoretical analysis: the cutting forces and indirectly cutting tool stresses, affecting the cutting tool life during machining in metal cutting, are one of very important parameters to be necessarily known to select the economical cutting conditions and to mount the workpiece on machine tools securely. In this paper, the cutting tool stresses (normal, shear and von Mises) in machining of nickel-based super alloy Inconel 718 have been investigated in respect of the variations in the cutting parameters (cutting speed, feed rate and depth of cut). The cutting forces were measured by a series of experimental measurements and the stress distributions on the cutting tool were analysed by means of the nite element method (FEM) using ANSYS software. ANSYS stress results showed that in point of the cutting tool wear, especially from von Mises stress distributions, the ceramic cutting insert may be possible worn at the distance equal to the depth of cut on the base cutting edge of the cutting tool. Thence, this wear mode will be almost such as the notch wear, and the ank wear on the base cutting edge and grooves in relief face. In terms of the cost of the process of machining, the cutting speed and the feed rate values must be chosen between 225 and 400 m/min, and 0.1 and 0.125 mm/rev, respectively. (ii) The mathematical modelling analysis: the use of articial neural network (ANN) has been proposed to determine the cutting tool stresses in machining of Inconel 718 as analytic formulas based on working parameters. The best tting set was obtained with ten neurons in the hidden-layer using back propagation algorithm. After training, it was found the R2 values are closely 1. 2008 Elsevier Ltd. All rights reserved.

Keywords: Inconel 718 Cutting tool stresses ANSYS Articial neural network (ANN)

1. Introduction In order to analyse the machining process, the nite element methods (FEM) which based on Eulerian and the updated Lagrangian formulation have been developed. In recent years, numerical models, especially the FEM, have been drawing attention the researchers due to computer technology and the complex codes development. Eulerian formulation in the number of the FEM models at the literature was used for the modelling of the orthogonal metal cutting. Because of Lagrangian formulation techniques ability to simulate the formation of the chip from the incipient stages to steady-state, it was used more widespread in metal cutting. To improve the accuracy and the efciency of the FEM in metal cutting, nite element techniques such as element separation criterion (Komvopoulos & Erpenbeck, 1991; Shih, 1995; Shih & Yang, 1993; Strenkowski & Caroll, 1985; Strenkowski & Mitchum, 1987; Ueda & Manabe, 1992), the modelling of the cutting tools wear (Shih, 1995; Shih & Yang, 1993; Strenkowski & Caroll, 1985; Strenkowski & Mitchum, 1987; Ueda & Manabe, 1992), re-meshing zone (Shih & Yang, 1993), friction modelling (Komvopoulos & Erpenbeck, 1991;
* Tel.: +90 312 202 86 26; fax: +90 312 212 00 59. E-mail address: akurt@gazi.edu.tr 0957-4174/$ - see front matter 2008 Elsevier Ltd. All rights reserved. doi:10.1016/j.eswa.2008.12.054

Shih, 1995; Shih & Yang, 1993; Strenkowski & Caroll, 1985; Strenkowski & Mitchum, 1987; Ueda & Manabe, 1992) etc., was used. In the literature for metal cutting with FEM, a large part of papers describe the simulation results on the chip formation process during orthogonal machining (Kalhori, Lundblad, & Lindgren, 1997; Shih, 1995; Usta, 1999; Zang & Bagchi, 1994) utilizing software such as Marc, Abaqus, Deform 2D/3D, Nike, Dyne, etc. In the FEM models on the chip formation process, the heat and chip formation (Maekawa & Shirakashi, 1996; Mansour, Osman, Sankar, & Mazzawi, 1973; Stevenson, Wrigt, & Chow, 1983; Strenkowski & Moon, 1990; Toshimichi, Nabuhiro, & Sheng, 1991), analysis of cutting tool wear (Komvopoulos & Erpenbeck, 1991), and residual stress distributions (Sadat, Reedy, & Yang, 1991) were investigated. Also, there are a lot of papers in the literature about the cutting tool stresses in respect of the variations in the cutting parameters. Seker and Kurt (2006) have investigated the effects of the cutting forces on the cutting tool stresses, and developed the mathematical models for the cutting tool stresses (mathematical modelling of the compressive stresses in x, y and z directions) in machining of nickel-based super alloy Inconel 718. They measured the cutting forces experimentally and analysed the stress distributions on the cutting tool by means of ANSYS software. They modelled the compressive stresses with multiple regression analysis regarding to ANSYS

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stress results depending on the cutting forces and the chiptool contact area, and showed that the model results had good agreement with the ANSYS stress results. The effects of the feed rate on the cutting tool stresses in machining of Inconel 718 were investigated by Kose, Kurt, and Seker (2008). They showed that the stresses on the ceramic insert increase with the increase of the feed rate, and the feed rate is the most relevant cutting parameter affecting cutting tool stresses. They found that the cutting tools stresses were inuenced by the feed force and the passive force values in comparison to the primary cutting force value. Kurt and Seker (2005) also investigated the effects of three different depth of cut (0.1, 0.2 and 0.4 mm) on the cutting tool stresses (normal, shear and von Mises stress) in machining of Al 2007 aluminium alloy orthogonally. In their FEM models, the primary cutting force and passive force on the cutting tool were applied as normal and tangential surface load on the rake and ank face by taking into account chip-tool contact length. The nite element analysis results showed that the normal stress in y-direction and shear stress in xy-plane decrease from tool tip to chip-tool contact length and their distributions are similar to Lee, Liu, and Lam (1995) and Zorevs (1963) normal and shear stress distributions. On the other hand, the stresses on the contact surfaces between the insert and the tip seat in the cutting tool were investigated by Wikgren (2001) using SNMG 120408-PM grade cutting tool (Sandvik, H10F) and SS2230 steel. Nickel-based super alloy Inconel 718 which is most noted for their outstanding strength and corrosion resistance (particularly at high temperatures), is known to be among the most difcultto-cut materials. In point of the poor machinability of nickel-based super alloys, especially of Inconel 718, are as follows (Dudzinski et al., 2004): a major part of their strength is maintained during machining due to their high-temperature properties. This super alloy is very strain rate sensitive and readily work-harden, causing further tool wear. The highly abrasive carbide particles contained in the microstructure cause abrasive wear. The poor thermal conductivity leads to high cutting temperatures up to 1200 C at the rake face. Nickel-based super alloys have high chemical afnity for many tool materials leading to diffusion wear. Welding and adhesion of nickel alloys onto the cutting tool frequently occur during machining causing severe notching as well as alteration of the tool rake face due to the consequent pull-out of the tool materials. Due to its high strength, the cutting forces reach high values, excite the machine tool system and may generate vibrations which compromise the surface quality. In terms of the machinability of Inconel 718 by the generation of the new cutting tools; the cutting tool wear, temperature distribution, high speed machining and the cutting tool geometries etc. subjects have drawn attention (ElWardany, Mohammed, & Elbestawi, 1996; Elbestawi, El-Wardany, Di, & Min, 1993; Kitagawa, Kubo, & Maekawa, 1997; Li, He, Wang, & Wang, 2002; Narutaki, Yamane, Hayashi, & Kitagawa, 1993). In the past years, regression analysis were the most common and popular modelling technique for prediction. However recently, the ANN availing engineering applications more viable attracts the potential users. Therefore, the use of ANN for modelling and prediction purposes is becoming increasingly popular in the recent years (Karatas, Szen, Arcakloglu, & Erguney, in press; Szen, Akayol, & Arcakloglu, 2006; Szen & Arcakloglu, 2007a, 2007b; Szen, Ar cakloglu, & Tekiner, in press; Szen, Glseven, & Arcakloglu, 2007; Szen, Menlik, & nvar, 2008). The use of ANN in metal cutting attracts researchers attention, especially subjects of tool wear (Filice, Micari, Settineri, & Umbrello, 2007; Ghosh et al., 2007; Luo, Cheng, Holt, & Liu, 2005; Panda, Chakraborty, & Pal, 2008; zel, Karpat, Figueira, & Davim, 2007; zel & Nadgir, 2002), optimization of machining parameters (Mukherjee & Ray, 2006; Muthukrishnan & Davim, 2009; Umbrello, Ambrogio, Filice, & Shivpuri, 2007; Umbrello, Ambrogio, Filice, & Shivpuri, 2008), and surface roughness

(Basheer, Dabade, Joshi, Bhanuprasad, & Gadre, 2008; Benardos & Vosniakos, 2002; Benardos & Vosniakos, 2003; Lu, 2008; Risbood, Dixit, & Sahasrabudhe, 2003; zel et al., 2007). ANNs are especially useful for prediction problems where mathematical formulae and prior knowledge on the relationship between inputs and outputs are unknown. In this paper, the effects of the variations in the cutting parameters (cutting speed, feed rate and depth of cut) on the cutting tool stresses (normal, shear and von Mises) during the machining of nickel-based super alloy Inconel 718 was investigated. The cutting forces were measured experimentally. The stress distributions on the cutting tool were analysed by nite element method using ANSYS (Kurt, 2006). Due to the experimental work costs are very high and required time to compute stresses is very long, the articial neural network (ANN) model is developed for all of the cutting tool stresses in machining of Inconel 718. 2. Materials and methods 2.1. The measurement of cutting forces In the cutting tests, nickel-based super alloy Inconel 718 (AMS 5663) with hardness of 4045 HRC was used as workpiece material. The chemical composition of Inconel 718 is shown in Table 1. Whisker reinforced ceramic inserts (Al2O3 + SiCw) with an ISO designation SNGN 120712 T01020 (Kennametal, KY 4300 grade) were used in the cutting tests. The inserts were mounted on a tool holder with an ISO designation, CSRNR 2525 M12 (Takimsas). Cutting tests were carried out on a JOHNFORD T35 CNC lathe. In total 50 tests were carried out without a coolant and ve different cutting speeds and feed rates, and two different depths of cut were used during the measurement of cutting forces. The cutting parameters used in the experiments are shown Table 2. The principal cutting force (FC), the feed force (Ff) and the passive/radial force (Fp) were measured by Kistler piezoelectric dynamometer Type 9257B.

Table 1 The chemical composition of Inconel 718 (AMS 5663). Element C Cr Fe Ni Mo S Mg Nb Ti Al Ta % 0.0120.06 1719 1619 5255 2.83.15 max. 0.001 max. 0.003 5.205.55 0.751.15 0.350.65 max. 0.1 Element Co O Mn Si P B Cu Ca Pb Bi Se % max. 1.0 max. 0.0025 0.060.10 0.060.09 0.010.015 0.0030.005 0.030.05 0.0050.01 0.000050.0001 0.000050.00001 0.000050.0001

Table 2 The test parameters. Workpiece material Cutting tool Modulus of elasticity (E, GPa) Poissons ratio (m) Tool holder Modulus of elasticity (E, GPa) Poissons ratio (m) Cutting parameters Cutting speed (V, m/min.) Feed rate (f, mm/rev.) Depth of cut (a, mm) Inconel 718 (AMS 5663) SNGN 120712 T01020 (KY 4300) 400 (Casto et al., 1999) 0.23 (Casto et al., 1999) CSRNR 2525 M12 210.7 (Lin & Lo, 1998) 0.28 (Lin & Lo, 1998) 225, 300, 350, 400, 500 0.05, 0.075, 0.1, 0.125, 0.15 1, 2

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2.2. FEM model of the cutting tool The distribution of stresses on the cutting tool was analysed by ANSYS based on the FEM using the cutting forces (FC, Ff and Fp) measured during the machining. In order to reduce the calculation time

in the analysis; the tool holder was modelled 50 mm length and the clamping components (clamp, shim, shim screw, etc.) to clamp the insert were neglected in the model. The process of the cutting tool modelling, by taking into account geometric properties of the cutting tools (rake angle, inclination angle, nose radius, chamfer angle,

Fig. 1. The solid and the nite element models of the cutting tools.

800 700 600 500

V=225 m/min
The depth of cut 1 mm 2 mm

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FC Ff Fp

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The depth of cut 1 mm 2 mm

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Fig. 2. The cutting forces in respect of the variations in the cutting parameters.

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clearance angles, etc.), was carried out by the solid model made up on Mechanical Desktop 6 Power Pack and than sent to ANSYS in .iges format. During the modelling of the cutting tools, the chiptool contact length (lc, indirectly the chiptool contact area, AC) was also

Fig. 3. Three dimensional stress state.

taken into account as well illustrated in literature (Kurt & Seker, 2005; Seker & Kurt, 2006; Toropov & Ko, 2003a, 2003b, 2005). The chiptool contact areas (AC) are 2.0308 and 8.0561 mm2 for the depth of cuts 1 and 2 mm, respectively. Thus, the solid models of the cutting tools, with taken into consideration the chiptool contact area, shown in Fig. 1, were developed according to the chiptool contact length and the depth of cuts. The material models for the ceramic insert and the tool holder were shown in Table 2 (modulus of elasticity and Poissons ratio were 400 GPa and 0.23 for the ceramic insert, and 210.7 GPa and 0.28 for the tool holder). SOLID92, three-dimensional 10-node tetrahedral structural solid with a quadratic displacement behaviour and well suited to model irregular meshes (such as produced from various CAD/CAM systems), was used as the element type for the cutting tools in the FEM model. The mesh density was selected

Fig. 4. Stress distributions (a) rx, (b) ry, (c) rz, (d) sxy, (e) re (V = 225 m/min, a = 2 mm, f = 0.15 mm/rev).

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too dense (smartsize = 3) in the chiptool contact areas and sparse (smartsize = 5) in the other parts of the cutting tool (Fig. 1). The contact pairs were also applied between cutting tool and the seat surface of the tool holder (3-D 8-node surface-to-surface contact element CONTA174 for the insert and 3-D target segment TARGE170 for the tool holder). In term of the solutions generated by ANSYS; 10237 (11931 nodes) and 26550 (29663 nodes) elements were used for CSRNR 2525 tool holder and SNGN 120712 T01020 ceramic insert, respectively. In spite of the clamping components (clamp, shim screw, etc.) were neglected in the solid model, the clamping forces applied to the insert by the clamping system were taken into consideration in the analysis. The clamping forces were applied to the clampto-insert contact zone as the nodal force, force/on nodes (Fig. 1). The cutting forces were applied to nodes in the chiptool contact areas (shaded area in Fig. 1) as follows: the primary cutting force was applied as triangular surface load throughout the chiptool contact length. The feed force (+x direction) and the passive force (y direction) were applied to nodes in the contact areas in the feed direction of the cutting tool and workpiece as the nodal force. In order to reduce the calculation time in the analysis, some of assumptions were performed as follows: the weight of the tool holder and the insert are neglected. The inserts used in the analysis are new and unused (sharp). The vibrations and temperatures occurred in the metal cutting are neglected in the analysis. The static analysis solution method was used. As a boundary condition for constraint, the degree of freedom of the nodes (nodal displacements) in the area to mount the tool holder to the dynamometer, on the tool holder mounting length, was selected zero in all directions (nodal displacements = 0). 2.3. Articial neural network (ANN) ANN is a system loosely modeled on the human brain. The brain consists of a large number of neurons, connected with each other by synapses. These networks are called as natural neural network (Szen & Arcakloglu, in press). The ANN is a simplied mathematical model of a natural neural network. It is a directed graph where a vertex corresponds to a neuron and an edge to a synapse (Anderson & McNeill, 1992). Different ANN models have been proposed since its conception in the 1940s, but the multi- layer perception (MLP) is the most widely used. These layered networks have been applied to various problems such as pattern recognition, prediction, and function approximation (Haykin, 1994). There are differ-

ent learning algorithms. A popular algorithm is the backpropagation algorithm, which have different variants. The goal of any training algorithm is to minimize the global error such as mean root-mean-square (RMS), mean absolute percentage error (MAPE) and R2. The error for hidden-layers is determined by propagating back the error determined for the output layer. These errors are explained as follows:

RMS MAPE

1=p

X
j

!1=2 jt j oj j
2

1 2 3

ot 100 o ! P 2 j t j oj 2 R 1 P 2 j oj
3. Stresses on the cutting tools 3.1. The experimental and theoretical analysis

The cutting forces measured by the cutting tests according to on the change in the feed rate value are shown in Fig. 2. In general, the cutting forces increase with the increase of the feed rate for all the cutting speed and the depth of cut. In all of the cutting experiments, the primary cutting force (FC) was measured too higher than other cutting forces. The measured cutting force values for the depth of cut 2 mm are higher than in the depth of cut 1 mm. Especially for the depth of cut 1 mm, the feed force (Ff) and the passive/radial force (FP) are nearly equal for all the cutting speed and the depth of cut. In order to explain three-dimensional stress state, a cube was used (Fig. 3). The stress results were interpreted with respect to Fig. 3a and b: stress signed + and was showed the form r ; r ; r ; s ; s ; s and r ; r ; r ; s ; s ; s , respectively. Norx y z xy yz xz x y z xy yz xz mal stresses and shear stresses were showed by symbol r and s, respectively: r ; r ; r and r ; r ; r pointed out the tensional x y z x y z and the compressive stresses in x, y, z axis, respectively. s ; s ; s xy yz xz and s ; s ; s pointed out the maximum shear stresses and the xy yz xz minimum shear stresses, respectively. re pointed out von Mises stress (or effective stress) (Fig. 3). Analyses were carried out for all 50 cutting experiments according to the stated loading condition. Fig. 4 shows the stress distributions for the cutting speed 225 m/min, the feed rate 0.15 mm/rev,

a FC Ff Fp AC Input layer

Bias

Hidden layer Bias Output layer

Fig. 5. ANN architecture.

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and the depth of cut 2 mm. The critical zone in terms of the cutting tool wear for the cutting speed 225 m/min, the feed rate 0.15 mm/ rev, and the depth of cut 2 mm, is determined as being equal to the depth of cut on the base cutting edge of the cutting tool (Fig. 4e). Generally, for all the cutting speeds, it is shown that all normal stress values are increase in parallel to the increase of the cutting speed regardless of the depth of cut. The highest value of the tensional normal stress compound in x-direction r is 1128.1 MPa x for the cutting speed 500 m/min, the feed rate 0.15 mm/rev, and

the depth of cut 2 mm. The highest values for tensional r and y r are 912.19 MPa and 1225.9 MPa at the depth of cut 2 mm for z V = 225 m/min, f = 0.15 mm/rev and V = 500 m/min, f = 0.15 mm/ rev, respectively. r ; r ; r compressive stresses are increase in x y z parallel to the increase of the depth of cut, but the variation of r is small than the other normal stress compounds. The compresz sive stresses for all tests may be lined up with respect to it is magnitude as r ; r ; r . The highest r ; r ; r stresses are 6006.5, x y z x y z 3585.8, and 910.36 MPa, respectively, for the cutting speed

1500

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ev m/r f (m

ANSYS (a=1 mm)

ANN (a=1 mm)

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ANN (a=2 mm)

TEST

Fig. 6. ANSYS vs. ANN results (normal stresses).

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500 m/min, the feed rate 0.15 mm/rev, and the depth of cut 2 mm. When tension stress is compared to compressive stress, in generally, it may be said that rx and ry stresses are more active as compressive stress. It also was observed that all of the maximum shear stresses increase in parallel at increasing of the feed rate for all the cutting speed and the depth of cut. The highest values for the maximum shear stresses on the xy and xz planes s ; s were obxy yz tained at the cutting speed 500 m/min, the feed rate 0.15 mm/

rev, and the depth of cut 2 mm (2779.1 and 2113.5 MPa, respectively). The highest value of the minimum shear stresses on the yz plane s was obtained as 1451.7 MPa at the same cutting conyz ditions. Also von Mises stresses (re) increase at increasing of the feed rate. Especially for the depth of cut 2 mm, the feed rate has signicant effect on von Mises stresses. For the cutting speed 225 m/min, re stress increased approximately 380 MPa at the depth of cut 1 mm, but it had an increase of 1352 MPa at the depth

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xz(MPa)
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) /rev (mm

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ev ) m/r f (m

ANSYS (a=1 mm)

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Fig. 7. ANSYS vs. ANN results (shear stresses).

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8000

e (MPa)

6400 4800

the cutting tool, in parallel with von Mises stress results for the cutting speed 500 m/min, the feed rate 0.15 mm/rev, and the depth of cut 2 mm (Fig. 4e). Thence, this wear mode will be almost such as the notch wear, and the ank wear on the base cutting edge and grooves in relief face. 3.2. Application results of ANN

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The selected different ANN structures are shown in Fig. 5. Variant of the algorithm used in the study is scaled conjugate gradient (SCG) with 10 neurons. Inputs and outputs are normalized in the (1, 1) range. Neurons in input layer have no transfer function. Each input is multiplied by a connection weight. In the simplest case, products and biases are simply summed, then transformed through a transfer function to generate a result, and nally the output obtained. Logistic sigmoid (logsig) transfer function has been used. The transfer function used:

Fig. 8. ANSYS vs. ANN results (von Mises stresses).

f z

1 1 ez

of cut 2 mm. The increasing in the cutting speed results in an increase in von Mises stresses. The effect of the feed rate on von Mises stresses can be clearly viewed for the cutting speed 500 m/ min. von Mises stresses results show that the highest stress value (7294.8 MPa) occurs again for the cutting speed 500 m/min, the feed rate 0.15 mm/rev, and the depth of cut 2 mm (for further information about normal stresses (tension, r+, and compressive, r), shear stresses (signed + and ), and von Mises stresses in respect of the variations in the cutting parameters, see Figs. 6 8). Analyses of the ceramic cutting insert made after the cutting experiments show that the highest cutting tool wear may be occur at the distance equal to the depth of cut on the base cutting edge of

where z is the weighted sum of the input. Computer program has been performed under MATLAB in order to use different algorithms and different neurons in the ANN. Inputs for the ANN are cutting speed (V), feed rate (f), depth of cut (a), the principal cutting force (FC), the feed force (Ff), the radial force (Fp), and the chiptool contact area (AC); outputs are the stress compounds (r , r , r , s , s , s , r , r , r , s , s , s , x y z xy yz xz x y z xy yz xz and re). Fig. 5 shows the single hidden-layer ANN architecture used in our application. The cutting tool stresses in machining of Inconel 718 are determined as analytic formulas in Eqs. (5)(17) by using articial neural network (ANN) based on working parameters. The new formulas of the output as the best algorithm SCG with 10 neurons is given Eqs. (5)(17).

1 1 e0:1323F 1 1:2949F 2 2:3202F 3 0:1361F 4 0:4726F 5 0:8911F 6 6:1122F 7 5:3649F 8 0:2013F 9 2:5397F 10 1:888 1 r y 1 e2:7401F 1 6:9103F 2 6:7309F 3 3:5864F 4 6:1363F 5 2:0115F 6 5:0066F 7 0:866F 8 3:5641F 9 1:034F 10 3:5476 1 r z 1 e1:6971F 1 1:4258F 2 1:8009F 3 2:0906F 4 3:4941F 5 2:8879F 6 1:7072F 7 3:5017F 8 2:0258F 9 1:791F 10 1:5205 1 s xy 1 e5:5977F 1 0:6556F 2 4:3353F 3 7:2282F 4 0:8674F 5 0:4761F 6 6:4609F 7 0:1679F 8 7:0464F 9 2:1686F 10 6:1648 1 s yz 1 e2:4589F 1 5:0055F 2 3:386F 3 3:1604F 4 4:2882F 5 1:0205F 6 3:3803F 7 2:4083F 8 2:9851F 9 0:8356F 10 1:6138 1 s xz 1 e1:2369F 1 1:1946F 2 1:9977F 3 1:4304F 4 0:3041F 5 0:3823F 6 4:489F 7 1:8487F 8 1:4753F 9 3:2417F 10 8:947 1 re 1 e2:7396F 1 0:8016F 2 5:9375F 3 3:5912F 4 0:9952F 5 0:2844F 6 5:7673F 7 2:3908F 8 3:4982F 9 2:5331F 10 3:1765 1 r x 1 e4:1115F 1 0:9804F 2 1:6629F 3 5:3972F 4 0:0067F 5 0:5784F 6 5:1742F 7 0:3727F 8 5:2103F 9 2:4636F 10 4:3061 1 r y 1 e2:908F 1 0:5195F 2 1:2668F 3 3:8217F 4 5:13F 5 0:7212F 6 2:9902F 7 1:1715F 8 3:6654F 9 1:1224F 10 4:3398 1 r z 1 e1:0329F 1 1:5357F 2 7:5405F 3 1:6108F 4 0:8181F 5 6:6672F 6 7:0688F 7 3:8515F 8 0:8046F 9 3:8289F 10 5:9102 1 s xy 1 e0:0668F 1 0:5064F 2 1:2967F 3 0:0575F 4 2:1739F 5 0:4926F 6 4:4223F 7 2:9913F 8 0:0405F 9 3:2349F 10 4:7216 1 s yz 1 e4:0411F 1 0:3254F 2 3:6262F 3 5:198F 4 6:8704F 5 1:0984F 6 5:022F 7 1:2504F 8 5:1132F 9 1:2332F 10 0:91 1 s xz 1 e1:5462F 1 0:848F 2 4:9161F 3 1:8481F 4 2:4873F 5 0:0858F 6 3:0012F 7 1:5014F 8 1:9367F 9 1:8951F 10 2:0603

r x

5 6 7 8 9 10 11 12 13 14 15 16 17

A. Kurt / Expert Systems with Applications 36 (2009) 96459657 0.3625 4.6662 3.5377 6.7162 1.9730 0.2820 9.1654 3.9512 7.9865 0.9430 Table 4 Values for normalization. Inputs V f a FC Ff Fp Ac Divided by Divided by 600 Multiplied by 6 Divided by 10 Divided by 1000 Divided by 700 Divided by 500 Divided by 10 Outputs Multiplied by Multiplied Multiplied Multiplied Multiplied Multiplied Multiplied Multiplied Multiplied Multiplied Multiplied Multiplied Multiplied Multiplied by by by by by by by by by by by by by

9653

C8i

13.8117 1.5777 1.8379 4.9758 0.3667 0.3857 6.7930 0.0349 0.5882 9.5156

r r r s s s

x y z xy yz xz

re

r x r y r z sxy s yz s xz

1200 1000 1500 3000 1000 2500 8000 7000 4500 1000 500 1600 700

C7i C6i

0.3578 6.2040 2.2030 9.2106 3.9923 0.0279 1.6467 1.1380 8.6653 0.8164

where; Fi can be calculated according to Eq. (18). The formulas for the prediction of the cutting tool stresses (Eqs. (5)(17)) is dependent on working parameters as seen in Eq. (19).

Fi
10.4281 8.6506 2.8684 2.2312 1.7618 2.7701 2.0701 5.4766 1.8896 7.9111

1 1 eEi

18

C5i

where Ei is given Eq. (19), which is working parameters.

Ei C 1i V C 2i f C 3i a C 4i F C C 5i F f C 6i F p C 7i AC C 8i 19

The constants (Cij) in Eq. (19) are given Table 3. The input and output values in network need normalizing according to Table 4. Figs. 68 present the simulated results versus the cutting tool stresses in machining of Inconel 718 experimental data for the testing database. Deviations between experimental results and theoretical results are very small for each parameter and negligible. Figs. 68 show the models ability to predict the cutting tool stresses values at different working parameters for Inconel 718. As seen from results ANN can be use the determination the cutting tool stresses. From this correlation and statistical test, it is evident that the model was successful in predicting the experimental data of the cutting tool stresses values. This shows the importance of the articial neural network to determine the cutting tool stresses. Table 5 and Figs. 911 show the performance of ANN. The statistical error values for these approaches are given Table 5.

C4i Table 3 The weights between input layer and hidden layer for scg10. C3i

18.6133 0.1004 6.4802 1.5629 0.0054 0.0042 0.0256 3.4063 1.3703 0.3375

2.1635 4.2188 4.3011 1.9316 2.2092 4.3290 3.5831 2.3149 2.4687 4.6573

1.7965 0.2546 4.7932 17.9616 0.1588 2.0432 0.1085 0.7424 19.0844 0.9373

C2i

4. Results and discussion The cutting tests on the Inconel 718 workpiece, using SNGN 120,712 T01020 ceramic cutting insert (KY 4300 grade), and the results of the ANSYS stress analysis are as follows: Although the resultant force for metal cutting is approximately the same for all the tests, the cutting tools stresses were inuenced by the feed force and the passive force values in comparison to the primary cutting force value in the machining of Inconel 718. The stresses on the ceramic insert increase with the increase of the feed rate. In respect of the depth of cut 2 mm, there is an inverse relationship between an increase in the cutting speeds and the stress values in the depth of cut 1 mm.

C1i i

1 2 3 4 5 6 7 8 9 10

0.3509 0.0221 0.8052 1.6874 0.0014 0.0117 0.0042 6.2742 1.7420 0.0787

9654 Table 5 The statistical error values. Output Training data RMS R
2

A. Kurt / Expert Systems with Applications 36 (2009) 96459657

Testing data MAPE 0.511668 0.800388 0.96822 0.494808 0.964464 0.539465 0.496114 0.477138 0.562041 0.821088 0.467795 0.457704 0.558552 RMS 0.00422 0.009387 0.006319 0.00428 0.003631 0.005328 0.002971 0.004131 0.006458 0.009149 0.004927 0.007215 0.006705 R2 0.999922 0.999489 0.999769 0.999917 0.999873 0.999871 0.999961 0.999915 0.999812 0.999794 0.999911 0.999823 0.999769 MAPE 0.945444 1.825894 1.401075 1.069269 0.739667 1.182814 0.69195 1.01595 1.239776 1.29199 0.868266 1.408554 1.556545

r r r s s s

x y z xy yz xz

re

r x r y r z s xy s yz s xz

0.005182 0.004981 0.00509 0.004619 0.004795 0.003344 0.003575 0.002591 0.003497 0.006189 0.003448 0.004019 0.003348

0.999904 0.999892 0.999886 0.999919 0.999853 0.999959 0.999954 0.999973 0.99995 0.999906 0.999963 0.999949 0.999952

1100 1000

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Fig. 9. The performance of ANN (normal stresses).

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A. Kurt / Expert Systems with Applications 36 (2009) 96459657

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9655

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Fig. 10. The performance of ANN (shear stresses).

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Fig. 11. The performance of ANN (von Mises stresses).

In terms of the cost of the process of machining, the cutting speed and the feed rate value must be chosen between 225 and 400 m/min, and 0.1 and 0.125 mm/rev, respectively. As a result of the cutting tools stress analysis, especially from von Mises stress distributions, in terms of the cutting tool wear, the ceramic cutting insert may be possible worn at the distance equal to the depth of cut on the base cutting edge of the cutting tool (actually, the ceramic insert worn at this distance in cutting tests (Kurt, 2006). Thence, this wear mode will be almost such as the notch wear (groove), and the ank wear on the base cutting edge and grooves in relief face. The results of validation and comparative study indicate that the ANN based estimation technique for the cutting tool stresses. This study conrms the ability of the ANN to predict the cutting tool stresses. The results indicate that the ANN model seems promising for evaluation powder ow in the known working parameters.

ANN stress results (MPa)

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Acknowledgements The author would like to thank Gazi University (Project Code: 07/200213) and The State Planning Organisation (Project Code: 2002K12025005) for providing nancial support for the project. Also, the author would like to thank Assoc. Prof. Dr. Adnan Sozen and Assoc. Prof. Dr. Erol Arcaklioglu for critically reviewing the original manuscript and application of ANN. References
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