Multi-objective optimization of ultrasonic-assisted magnetic abrasive finishing process

Abstract

Ultrasonic-assisted magnetic abrasive finishing (UAMAF) is an advanced abrasive finishing process that finishes a workpiece surface effectually when compared to a traditional magnetic abrasive finishing process in the order of nanometer. A change of surface roughness and material removal rate are two important factors determining the efficacy of the process. These two factors affect the surface quality and production time and, thereby, a total production cost. The finishing performed at higher material removal rates leads to a loss in shape/form accuracy of the surface. At the same time, increasing the rate of change of surface roughness increases loss of material. For an optimized finishing process, a compromise has to be made between the change of surface roughness and the material removal (loss). In this work, a multi-objective optimization technique based on genetic algorithm is used to optimize the finishing parameters in the UAMAF processes. A fuzzy-set-based strategy for a higher level decision is also discussed. The results of the optimization based on a mathematical model of the process are validated with the experimental results and are found to be in compliance.

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Funding

Funding was from the Engineering and Physical Sciences Research Council (UK) through grant EP/K028316/1 and Department of Science and Technology (India) through grant DST/RC-UK/14-AM/2012 for project “Modeling of Advanced Materials for Simulation of Transformative Manufacturing Processes (MAST)” .

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Correspondence to Pulak M. Pandey.

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Misra, A., Pandey, P.M., Dixit, U.S. et al. Multi-objective optimization of ultrasonic-assisted magnetic abrasive finishing process. Int J Adv Manuf Technol 101, 1661–1670 (2019). https://doi.org/10.1007/s00170-018-3060-0

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Keywords

  • UAMAF
  • Finishing
  • Multi-objective optimization
  • Genetic algorithm
  • Material removal
  • Surface roughness
  • Fuzzy sets