Optimization of turning parameters by using design of experiments and simulated annealing algorithm based on audible acoustic emission signals

The direct measurement of flank wear at regular intervals of time during machining consumes men and machine hours. This analysis focuses on the online monitoring of flank wear in turning from the experimentally observed audible acoustic emission signal. It is used as one of the indirect methods of monitoring flank wear in turning. The corresponding flank wear in all the test conditions for a machining time of 300 s are observed and recorded. When the value of the audible acoustic emission signal tends to reach the unsafe limit corresponding to the flank wear of above 0.2 mm, the operator is alerted to stop the operation to replace the tool. This technique minimizes the tool cost without sacrificing the quality of the final product. Also, this analysis inter-relates the performances of the design of experiments, regression analysis and simulated annealing algorithm to obtain the best possible solution. The result of this analysis identifies the optimal values of selected parameters for effective and efficient machining. The experimental, optimized and predicted values of flank wear are compared and correlated with the experimental audible acoustic emission signal.