Predictive modeling of drilling operation for optimum MRR, machine power, and estimated tool life using fuzzy logic and regression analysis

Abstract

Models prediction is done for accurately anticipating metal removal rate (MRR), machine power (MP), and estimated tool life (ETL), which are vital in the industrial setup for better precision and higher speed. Cutting speed (CS) and feed rate (FR) were employed as controlling parameters for machining of P8 material on the SBCNC 60. By maintaining one of the two parameters constant at the mid-level, data from drilling experiments are sampled and examined. Application of ANOVA yields that the feed rate is 52.61 percent significant and the cutting speed is 46.49 percent significant for MRR, while cutting speed contributes 57.59 percent and feed rate contributes 41.77 percent to the machine power, and the same cutting speed contributes 83 percent to ETL’s output. The analysis results that CS at 190 m/min and FR at 0.3 mm/rev are optimal combinations of input control parameters for all output of drilling operations. The development of prediction models is done by fuzzy and its comparison is carried out with classical regression method for the achievement of optimum MRR, MP and ETL. Numerical parameters for establishing the optimum model are calculated for MAPE, RMSE, MAD, and correlation coefficient between experimental values and the values obtained from regression, and fuzzy logic predictions. MAPE, RMSE, MAD, and correlation coefficient calculated 1.27%, 2.43, 1.89, and 0.99 for MRR,0.97%,0.10, 0.09 and 0.997 for MP and 5.12%,1.01,0.67 and 0.99 for ETL respectively. Hence, the proposed fuzzy logic rules effectively predict the MRR, MP, and ETL on P8 material with optimized performance.