Introduction

Machining or metal cutting is one of the important and widely used manufacturing processes
in engineering industries. Out of many types of machining operations, turning is the key value-
adding metal cutting process required to produce assembly components and final products.
The higher productivity, in manufacturing by turning operation, insists high material removal
rate. The material removal rate increases with an increase in velocities and feed rates but it
also raises the cutting temperature considerably and high cutting temperatures strongly
influence chip formation mechanism, tool wear, tool life, and workpiece surface integrity. In
such a scenario, applications of optimization techniques in metal-cutting processes are
essential for a manufacturing unit to respond effectively to productivity-related
competitiveness and increasing demand for quality products in the market. Application of
optimization techniques in metal cutting processes is required is to be undertaken in two
stages: firstly, modeling of input-output and in-process parameter relationship, and secondly,
determination of optimal or near-optimal cutting conditions. Optimal or near-optimal
solution(s) provided by optimization technique is subsequently implemented in the actual
metal-cutting process for better productivity and product quality.
Modeling of input-output and in-process parameter relationship is considered an abstract
representation of a process linking causes and effects or transforming process inputs into
outputs (Markos Viharos, & Monostori, 1998). In this research work, the input parameters are
cutting speed, feed rate, and depth of cut, and the output parameters are cutting temperature
and MRR. Cutting temperature and MRR are the effects where the causes are cutting speed,
feed rate, and depth of cut. Multiple Regression technique is used to develop the empirical
model, a functional relationship between output and input decision variables of a cutting
process. The resulting model provides the basic formulation of the process objective function.
In this research work, a metaheuristic search technique known as non-dominated sorting
genetic algorithm II (NSGA-II) is implemented for multi-objective optimization, which
maximizes MRR while the cutting temperature is minimized. Subsequently, support vector
machine (SVM) is a machine-learning method based on the statistical learning theory that is
implemented to determine optimal or near-optimal cutting conditions.
So far, this research is nothing exceptional as a number of researchers already have done this
type of work. The novelty of this research work is that, a finite element method-based
modeling of input-output and in-process parameter relationships. The optimal or near-optimal
cutting conditions found from finite element method-based modeling are compared with the
optimal cutting conditions previously found. Finite element simulation is an effective tool to
evaluate the metal cutting process including chip forming simulation, cutting force simulation,
wear simulation, etc. In this research work DEFORM 3D (Ohio, USA) is used which is a
powerful software for the simulation and analysis of metal cutting processes. Johnson-Cook
material constitutive model is used as it is simple in form and widely used by other
researchers. It is an ideal model of elastic-plastic strengthening. The model is suitable for the
temperature range from room temperature to the melting point of the material. So, the J-C
constitutive reinforcement model was selected. This thermo-elastic-visco-plastic material
constitutive model consists of three terms, a temperature softening term which accounts for the
decrease of flow stress due to heat, the viscosity term emphasizes that material flow stress
increases with strain rate and the elastic-plastic term represents strain hardening.
As the research work focuses to increase the MRR while the cutting temperature is minimum
and an increase in MRR increases both the viscosity effect and thermal softening, the objective
is to maximize the viscosity effect and minimize thermal softening. Strain hardening is not a
concern for the FEM-based modeling of this research work. In the new input-output and in-
process parameter relationship, input parameters are cutting speed, feed rate, and depth of cut,
and the output parameters are viscosity effect and thermal softening effect proportions.
Similarly, as earlier, the objective functions of these output variables are developed using
multiple regression then NSGA-II is implemented to maximize the viscosity effect and
minimize thermal softening and optimal or near-optimal cutting conditions are determined
using SVM. This research work makes its conclusion based on the comparison of these cutting
conditions and the cutting conditions found from the explicit mathematical model earlier.

Literature Review
A traditional machining operation involves removing material from a piece of material in the
form of chips using single or multi-point tools. In modern machining, workpieces are
machined and materials are removed by using chemical, thermal, or electrical processes. The
EDM process was modeled using ANN and optimized using NSGA II by Mandal et
al. According to the author, this model can predict process parameters based on the results of
the experiment. 

In a study by Kanagarajan et al., tungsten carbide and cobalt composites were evaluated for
their efficacy in the EDM process. The effect of electrode rotation, pulse current, and flushing
pressure on the material removal rate and surface roughness are studied. A second-order
polynomial equations-based machining model was used for the analysis of the processing
conditions and NSGA-II was used to optimize ECM cutting parameters (electrolyte
concentration, electrolyte flow rate, applied voltage, and tool feed rate) using NSGA-II for
maximizing MRR and minimizing surface roughness.           

A modeling process using the finite element method (FEM) and neural network (ANN) and
genetic algorithm (GA) was reported by Joshi et al. to predict the shape of craters, MRR, and
tool wear rate. The model uses an ANN to relate the process parameters (current, discharge
voltage, duty cycle, and discharge duration) and the machining performance (crater size,
MRR, and TWR). FEM data was used to train, test, and tune the ANN model. NSGA-II was
used to select the optimal process parameter for EDM. Experimental results were compared
with results obtained from the proposed approach for verification. EDM will therefore perform
at its optimal level with the proposed approach.    

Kondayya et al. introduced an integrated evolutionary approach. The genetic programming

(GP) approach has been proposed for modeling highly nonlinear and complex processes.
WEDM machining performance, metal removal rate, and surface roughness are modeled using
GP based on experimental data. NSGA-II is used to solve the multi-objective optimization
problem of machining performances. The Pareto optimal solution is derived by using an
evolutionary approach for optimization.

Mitra et al. explored in adapting NSGA-II for optimizing the industrial grinding operation of a
lead-zinc ore beneficiation. Maximizing the throughput of the grinding product and
maximizing the proportion of midsize passing are two objective functions taken into account
in this study. The solid ore flow rate, primary water flow rate, and secondary water flow rate
are the three process parameters that are optimized. The spread of the Pareto front determined
by the NSGA-II optimization technique and the SOOP formulation for MOOP (Multi-
Objective Optimization Problem) utilizing a weighted average approach or constraint-based
approach were compared by the authors. It can be said that NSGA-II produces better quality
Pareto fronts than the other technique. 

Kodali et al. solved a problem including two objectives, four constraints, and ten decision
variables for the grinding machining procedure using NSGA-II. The Pareto-optimal front
achieved is compared with previously reported findings of differential evolution (DE),
quadratic programming (QP), quadratic programming (GA), PSO, scatter search (SS), and
ACO, and it reveals that NGSA II outperformed others.

R. Datta et al. presented a study on maximizing the cutting speed, feed, and depth of cut for a
turning operation. Minimizing production time, production cost, and surface roughness are the
goals that have been taken into account. A better solution is obtained using NSGA II-based
Pareto-optimal front. 

The work by Latha et al. is focused on the three objective multiple performance optimizations
of drilling parameters in drilling of the composite drilling process. In this study, the process
parameters and machining performances that are considered include spindle speed, feed speed,
and drill diameter on maximizing material removal rate and reducing thrust force and surface
roughness. Computer numeric control (CNC) drilling equipment and carbide drill bits were
used for the experiments. To maximize the drilling conditions, second-order regressions are
created and NSGA-II is applied. The approach is appropriate for obtaining the Pareto frontier
when optimizing drilling parameters because a non-dominated solution set has been obtained.

Jianling proposed a modified NSGA-II to address the various milling operational constraints.

Both reduced machining time and minimum tool life were taken into consideration. The
optimization process becomes more approximative to application, more economical, and more
effective in searching the Pareto front by extending the non-dominance concept to the NSGA-
II constraint space.
In order to improve the machining properties of glass fiber reinforced plastic (GFRP)
composites, Palanikumar et al. researched numerous performance optimization. Cutting speed,
feed, and depth of cut were taken into consideration. It was decided to use second order
polynomial equations to explain the dependent and independent variables. The cutting
conditions were optimized with NSGA-II, and the shorter machining times made it possible to
significantly increase production rates. 

By combining the NSGA-II and the multi-objective differential evolution (MODE)

method, Yang et al. were able to solve the multi-objective optimization problem in turning.
Cutting speed, feed rate, and depth of cut are taken into consideration when machining
components. Regression models were used to increase material removal rate while reducing
tool wear (MRR). When the non-dominated solution set from MODE was compared to that
from NSGA-II, it was discovered that NSGA-II performed better than MODE in terms of both
the number of solutions and the proportion of non-dominated persons.

Methodology

Finite Element Formulation

Finite Element Formulation. Mesh descriptions, kinetics, and kinematics descriptions

differentiate the formulations. In particular, when dealing with nonlinearity and large
deformations, selecting the appropriate formulation or approach is of prime importance. In
finite element machining, Lagrangian, Eulerian, and Arbitrary Lagrangian Eulerian are three
of the most commonly used formulations. As every formulation has its advantages and
disadvantages, the usage of this formulation may differ from each other, a comparative
discussion is given in the following sections.
 (a) Eulerian, (b) Lagrangian, and (c) ALE meshing

Lagrangian Formulation
In the Lagrangian approach, the location of the material points relative to the nodes remains
fixed even if both the material points and nodes change positions when the body deforms. It is
easier to impose boundary conditions and interface conditions because boundary nodes
frequently stay close element edges as the problem evolves. Constitutive equations are treated
simply because quadrature points continue to be coinciding with the material points, indicating
that they are always assessed at the same material points. In solid mechanics, Lagrangian
approaches are widely used for these reasons. In this approach, mesh distortion may occur due
to mesh deformation caused by material deformation. Large deformations may harm the
performance of FE simulations in cases involving large deformations. One of the ways
researchers overcome distortion problems is to use pre-distorted meshes or remesh the model.
Lagrangian formulation has been used by many researchers in metal cutting models because it
is easy to implement and is computationally efficient. First, Klamecki used the finite element
method to model machining processes. Strenkowski et al. used a Lagrangian formulation
modified to include plane strain for modeling orthogonal cutting . In addition, they
incorporated a friction model along the tool rake face as well as a simplified adiabatic heating
model. In the work of Marusich et al., continuous and adaptive remesh were utilized, which
captured a transition from a continuous to a segmented chip as tool speed increased.

Eulerian Formulation
An Eulerian approach has a fixed reference frame in space that allows the material to flow
through it. Numerical difficulties caused by the distortion of elements are eliminated since the
mesh is fixed in space. The simulation is performed without using any mesh separation
criteria. In Eulerian formulations, free boundaries cannot be modeled because they are not
coincident with the nodes that make up the boundary. The boundary of the deformed material
must be known a priori for this to work. Thus, chip dimensions must be specified in advance
for a predictive Eulerian model to be produced. In addition, handling and updating constitutive
equations becomes difficult because material flows through the mesh, i.e. element quadrature
points may not coincide with material points. Modeling the metal cutting process using
Eulerian formulation is often limited by these drawbacks. Raczy et al. have employed this
formulation which predicted the stress and strain distributions of an orthogonally machined
copper workpiece.

Arbitrary Lagrangian-Eulerian (ALE) Formulation

Both Eulerian and Lagrangian approaches have their advantages and disadvantages. With
ALE formulations, nodes can be programmed arbitrarily so that the advantages of both
Lagrangian and Eulerian formulations can be exploited and combined while minimizing their
disadvantages. To minimize mesh distortion, interior nodes are moved to minimize mesh
distortion, while boundary nodes remain on the boundaries. ALE reduces the form on free
boundaries to a Lagrangian form during the simulation of the metal-cutting process while
maintaining an Eulerian form at locations where significant deformation occurs. Furthermore,
this technique eliminates the need for a priori assumptions about chip shape and reduces mesh
distortion without re-meshing. This method is computationally efficient, but it is still limited
by the mesh and smoothing algorithm chosen. The ALE formulation was used for the first time
by Olovsson et al. to model a 2D machining finite element model.
 Results and discussion

Conclusion and Discussion