Optimization of responses in single and multi-point machining processes using Dragon-fly algorithm coupled with TOPSIS and VIKOR decision-making approaches

Abstract

Abstract Due to complex production practices, it is becoming crucial to provide greater thermal management and friction reduction in manufacturing processes. Lubricants play a crucial role by effectively reducing friction, minimizing wear and tear thereby extending the lifespan of the tool. It is observed that there is a shortage of studies associated with the machining of hard materials like Ti-6Al-4V. The present work has therefore focused on the machining of high-grade Titanium alloy under dry and Neem oil aerosol-mist spray wet conditions. The machining is performed on two kinds of machining processes, such as plain facing with single point tool and co-axial turn-mill facing with multi-point cutting tools on computer numerical controlled Turn-mill machine tool. Furthermore, there are very few articles reported on usage of Neem oil (AzadirachtaIndicaL.) as a lubricant. This has motivated the authors to use Neem oil in a mist condition to minimize the quantity of coolant, without compromising on the tool temperature, surface quality, and tool-wear. The responses obtained are subjected to regression analysis to evolve the fitness functions. Multi-objective optimization of these functions is than adopted using Dragon-fly algorithm (MODA) under the constraints of the machining parameters. A set of pareto optimal solutions for each of the machining cases are obtained and are further evaluated using TOPSIS and VIKOR decision-making approaches to achieve the optimal values of the cutting parameters. The optimum parameters for single point cutting under wet conditions were observed as speed (592 rpm), feed (0.058 mm rev−1) and depth of cut (1.00 mm).The corresponding values of responses were tool temperature (37.05 °C), surface roughness (0.128 μm) and tool wear (155.19 μm). The equivalent values for multi-point cutting were determined as 510 rpm, 0.086 mm rev−1 and 0.25 mm. The responses for these optimal conditions are 32.17 °C, 0.725 μm and 45.72 μm in that order.