Optimization of cutting conditions using artificial neural networks and the Edgeworth-Pareto method for CNC face-milling operations on high-strength grade-H steel

Computer Numerical Control (CNC) face milling is commonly used to manufacture products from high-strength grade-H steel in both the automotive and the construction industry. The various milling operations for these components have key performance indicators: accuracy, surface roughness (Ra), and machining time for removal of a unit volume min/cm3 (Tm). The specified surface roughness values for machining each component is achieved based on the prototype specifications. However, poor adherence to specifications can result in the rejection of the machined parts, implying extra production costs and raw material wastage. An algorithm using an artificial neural network (ANN) with the Edgeworth-Pareto method is presented in this paper to optimize the cutting parameter in CNC face-milling operations. The set of parameters are adjusted to improve surface roughness and minimal unit-volume material removal rates, thereby reducing production costs and improving accuracy. An ANN algorithm is designed in Matlab, based on a 3–10-1 Multi-Layer Perceptron (MLP), which predicts the Ra of the workpiece surface to an accuracy of ± 5.78% within the range of the experimental angular spindle speed, feed rate, and cutting depth. An unprecedented Pareto frontier for Ra and Tm was obtained for the finished grade-H steel workpiece using an ANN algorithm that was then used to determine optimized cutting conditions. Depending on the production objective, one or the other of two sets of optimum machining conditions can be used: the first one sets a minimum cutting power, while the other sets a maximum Tm with a slight increase (under 5%) in milling costs.