Predictive modeling of surface roughness in hard turning with rotary cutting tool based on multiple regression analysis, artificial neural network, and genetic programing methods

Abstract

This present paper deals with the results of setting up and evaluating the quality of surface roughness (SR) prediction models through hard turning with self-driven rotary cutting tools for 40X steel shaft with hardness 45HRC. The cutting parameters are considered to establish the SR prediction model include angle tilt of cutting tool axis, depth of cut, feed rate, and cutting speed. The predictive models (PM) are established utilizing Multi-variables Regression Analysis (MRA), Artificial Neural Network (ANN), and Genetic Programming (GP) methods. In this regard, four MRA, four ANN, and three GP structures are considered to select the most suitable model. The criteria to estimate the PM quality include Coefficient of Determination ( R2), Mean Square Error (MSE), and Mean Absolute Percent Error (MAPE). Whereby, two data sets were collected to construct regression models (RM) and to serve verification. That dataset was originated from 63 experiments (Ep) including 54 Ep for establishing PM and 9 extensive experiments (EEp) for testing PM. The prediction criteria of the MRA3 model gave the best results in four MRA models with R2 of 0.99, MSE of 0.042, and MAPE of 8.087%. The ANN1 gives the most reliable assessment criteria in four ANN models and the GP3 model gave the best in three GP models. The results of predicting the SR value between the selected MRA and ANN and GP models will be assessed in detail. Accordingly, the evaluation criteria of the ANN1 model are the best with the smallest MSE (0.032) and MAPE (7.207%). The MRA3 and GP3 have a lower confidence predictive criteria value than the ANN1 model.