Assessment of performance parameters in intermittent turning and multi-response optimization of machining conditions using DF, MOORA, VIKOR, and coupled NSGAII-VIKOR methods

This study aims to assess the influence of different machining factors (Vc, f, ap, and r) during intermittent turning of cold work tool steel (AISI D3). Eight output parameters were examined, namely surface roughness (Ra), cutting force (Fz), motor power (Pm), flank wear (VB), cutting temperature (Ct), material removal rate (MRR), tangential vibration (Az), and sound intensity (Lp). A statistical study based on ANOVA was conducted to quantify the effects of cutting factors on output parameters. The results revealed that (Vc) has a predominant influence on outputs (Pm, VB, Ct, and Lp), with respective contributions of 40.37%, 66.44%, 29.72%, and 47.64%. Additionally, the factor (ap) was identified as the dominant factor for (Fz and Az), with contributions of 51.82% and 74.07%. Finally, the factor (f) is most significant for (Ra), with a contribution of 57.86%. The application of Response Surface Methodology (RSM) allowed for the development of accurate mathematical models to predict these outputs, characterized by a determination coefficient exceeding 92.28%. Ultimately, four multi-objective optimization approaches, namely DF, MOORA, VIKOR, and NSGAII coupled with VIKOR, were used to determine the optimal combination of cutting conditions. These four methods were examined and compared. The results indicate that the DF approach offers the best combination of parameters: r = 1.29 mm, Vc = 240 m/min, f = 0.1 mm/rev, and ap = 0.689 mm, leading to the minimization of six outputs (Ra, Pm, Ct, VB, Fz, and Lp) with respective values of 0.825 µm, 3282.085 Watt, 0.066 mm, 211.683 °C, 82.837 N, and 108.158 dB. On the other hand, the MOORA approach favors the minimization of vibrations (Az), with a value of 15.01 m/s2, while VIKOR presented five outputs (Pm, VB, Ct, MRR, and Lp) superior to the MOORA approach. Finally, the NSGAII approach coupled with VIKOR exhibited the best productivity value (MRR) with a rate of 405.636 mm3/s.