Sustainability-Based Optimization of the Rotary Turning of the Hardened Steel

Abstract

The rotary turning is an effective manufacturing method to machine hardened metals due to longer tool life, higher production rate, and acceptable quality. However, sustainability-based optimization of the rotary turning has not been thoroughly considered because of the huge efforts. This study presents an optimization to enhance the energy efficiency (EFR), turning cost (CT), average roughness (Ra), and the operational safety (POS) for the rotary turning of the hardened steel. Four key process parameters considered are the inclined angle (α), depth of cut (ap), feed rate (f), and cutting speed (vc). The improved Kriging (IK) models were used to construct the relations between the parameters and performances. The optimum varied factors were obtained utilizing the neighborhood cultivation genetic algorithm (NCGA). The findings revealed that the performance models are primarily affected by the feed rate, depth of cut, speed, and inclined angle, respectively. The optimal values of the α, ap, f, and vc are 26°, 0.44 mm, 0.37 mm/rev, and 200 mm/min, respectively. The improvements in energy efficiency, average roughness, and cost are 8.91%, 20.00%, and 14.75%, as compared to the initial values. Moreover, the NCGA may perform an efficient operation to obtain the optimal outcomes, as compared to conventional algorithms.

Keywords

• rotary turning
• energy efficiency
• average roughness
• cost
• optimization
• key process parameters