Sensitivity analysis of the artificial neural networks in a system for durability prediction of forging tools to forgings made of C45 steel

The article presents the results of a sensitivity analysis of artificial neural networks developed for a system which predicts the durability of forging tools used in the selected hot die forging process. The developed system makes it possible to calculate the geometric loss of the examined tool for the given values of its operating parameters (number of forgings, tool temperature at selected points, type of the applied protective layer, pressure and path of friction) and estimates the intensity of the occurrence of typical mechanisms of tool destruction, i.e. thermo-mechanical fatigue, mechanical wear, abrasive wear and plastic deformation. Nine neural networks operate in the developed system. Five of them determine the geometric loss of the material used for tools operating with protective layers, including a nitrided layer, a pad welded layer and three hybrid layers, i.e. AlCrTiSiN, Cr/CrN and Cr/AlCrTiN. Four networks make calculations determining the intensity of the occurrence of typical destructive mechanisms. The developed sensitivity analysis allows for each neural network to show which input parameters are most important and have the greatest impact on the explained variables. This is determined based on the network error analysis in the case of elimination of individual variables from the input data. The greater the network error calculated after rejecting an input variable relative to the error obtained for the network with all the input variables, the more sensitive the network to the lack of this variable. The best compliance was obtained for the first developed set of networks regarding the geometric loss of material, while the lowest compliance was obtained for the second developed set of networks regarding the applied protective layers, and in particular for plastic deformation and mechanical fatigue, probably due to the smallest size of these sets in the knowledge base. The obtained results of this analysis are important for the system operation, i.e. supporting the technologist’s decision in the selection of such process parameter values that will increase the die’s lifetime.