GEP- and ANN-based tool wear monitoring: a virtually sensing predictive platform for MQL-assisted milling of Inconel 690

  • Binayak Sen
  • Mozammel MiaEmail author
  • Uttam Kumar Mandal
  • Sankar Prasad Mondal


Inconel 690 is an extensively used superalloy in the aerospace and nuclear industries. Owing to the low thermal conductivity and poor machinability, the cutting tools are severely affected during the milling of Inconel 690. Thus, the machining of such superalloys consumes an extensive cost and time. In this context, an artificial intelligence–assisted cost-effective meta-model has been established in this manuscript for the accurate prediction of maximum flank wear. Here, a series of experiment was conducted on Inconel 690 using a TiAlN-coated solid carbide insert. Afterward, using the main effect plot (MEP) diagram, the effects of machining parameters on flank wear were evaluated. Additionally, the analysis of variance (ANOVA) demonstrated that the MQL flow rate is the most significant parameter affecting the flank wear. In the second part, 70% of machining output has been selected for training the gene expression programming (GEP) and artificial neural network (ANN) model, and the rest 30% data has been used for testing purpose. Furthermore, considering a statistical platform, the GEP model has been compared with an ANN model. The comparative analysis demonstrated that the GEP meta-model is superior to the ANN model in predicting the maximum flank wear under MQL environment. The outcomes of this study can aid the metal cutting industries to better plan the machining system on the perspective of the tool wear reduction with optimized parameters levels.


Inconel 690 MQL-milling Flank wear GEP ANN 



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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  • Binayak Sen
    • 1
  • Mozammel Mia
    • 2
    Email author
  • Uttam Kumar Mandal
    • 1
  • Sankar Prasad Mondal
    • 3
  1. 1.Production EngineeringNational Institute of TechnologyAgartalaIndia
  2. 2.Mechanical and Production EngineeringAhsanullah University of Science and TechnologyDhakaBangladesh
  3. 3.Department of Natural ScienceMaulana Abul Kalam Azad University of Technology, West BengalHaringhataIndia

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