Experimental Investigation for the Multi-objective Optimization of Machining Parameters on AISI D2 Steel Using Particle Swarm Optimization Coupled with Artificial Neural Network

High Carbon High Chromium (or AISI D2) Steels, owing to the fine surface finish they produce upon grinding, find lot of applications in die casting. Machining parameters affect the surface finish significantly during the grinding operation. In this context, this work puts an effort to arrive at the optimum machining parameters relating to fine surface finish with minimum cutting force. The material removal caused by the abrasive grinding wheel makes the process a very complex and nonlinear machining operation. In many situations, traditional optimization techniques fail to provide realistic optimum conditions because of the associated complexity. In order to overcome this issue, particle swarm optimization (PSO) coupled with artificial neural network (ANN) is applied in this research work for parameter optimization with the objective of achieving minimum surface roughness and cutting force. The machining parameters selected for the investigation were table speed, cross feed and depth of cut and the responses were surface roughness and cutting force. ANNs, inspired from biological neural networks, are well capable of providing patterns, which are too complex in behavior. The ANN model developed was used as the fitness function for PSO to complete the optimization. Optimization was also carried out using conventional response surface methodology-genetic algorithm (RSM-GA) approach in which regression equation developed with RSM was considered as the fitness function for GA. Confirmatory experiments were conducted and the comparison showed that PSO coupled with ANN is a reliable tool for complex optimization problems.