Magnesium alloys are widely used in aerospace vehicles and modern cars, due to their rapid machinability at high cutting speeds. A novel Edgeworth–Pareto optimization of an artificial neural network (ANN) is presented in this paper for surface roughness (Ra) prediction of one component in computer numerical control (CNC) turning over minimal machining time (T_m) and at prime machining costs (C). An ANN is built in the Matlab programming environment, based on a 4-12-3 multi-layer perceptron (MLP), to predict Ra, T_m, and C, in relation to cutting speed, v_c, depth of cut, a_p, and feed per revolution, f_r. For the first time, a profile of an AZ61 alloy workpiece after finish turning is constructed using an ANN for the range of experimental values v_c, a_p, and f_r. The global minimum length of a three-dimensional estimation vector was defined with the following coordinates: Ra = 0.087 μm, T_m = 0.358 min/cm³, C = $8.2973. Likewise, the corresponding finish-turning parameters were also estimated: cutting speed v_c = 250 m/min, cutting depth a_p = 1.0 mm, and feed per revolution f_r = 0.08 mm/rev. The ANN model achieved a reliable prediction accuracy of ±1.35% for surface roughness.

Computer Numerical Control (CNC) face milling is commonly used to manufacture products from high-strength grade-H steel in both the automotive and the construction industry. The various milling operations for these components have key performance indicators: accuracy, surface roughness (Ra), and machining time for removal of a unit volume min/cm³ (T_m). The specified surface roughness values for machining each component is achieved based on the prototype specifications. However, poor adherence to specifications can result in the rejection of the machined parts, implying extra production costs and raw material wastage. An algorithm using an artificial neural network (ANN) with the Edgeworth-Pareto method is presented in this paper to optimize the cutting parameter in CNC face-milling operations. The set of parameters are adjusted to improve surface roughness and minimal unit-volume material removal rates, thereby reducing production costs and improving accuracy. An ANN algorithm is designed in Matlab, based on a 3–10-1 Multi-Layer Perceptron (MLP), which predicts the Ra of the workpiece surface to an accuracy of ± 5.78% within the range of the experimental angular spindle speed, feed rate, and cutting depth. An unprecedented Pareto frontier for Ra and T_m was obtained for the finished grade-H steel workpiece using an ANN algorithm that was then used to determine optimized cutting conditions. Depending on the production objective, one or the other of two sets of optimum machining conditions can be used: the first one sets a minimum cutting power, while the other sets a maximum T_m with a slight increase (under 5%) in milling costs.

Aluminum Alloy 6061 components are frequently manufactured for various industries—aeronautics, yachting, and optical instruments—due to their excellent physical and mechanical properties, including corrosion resistance. There is little research on the mechanical tooling of AA6061 and none on its structure and properties and their effects on surface roughness after finish turning. The objective of this comprehensive study is, therefore, to ascertain the effects of both the modern method of hardening AA6061 shafts and the finish turning conditions on surface roughness, Ra, and the minimum machining time for unit-volume removal, T_m, while also establishing the cost price of processing one part, C. The hardening methods improved both the physical and the mechanical material properties processed with 2, 4, and 6 passes of equal channel angular pressing (ECAP) at room temperature, using an ECAP-matrix with a channel angle of 90°. The reference workpiece sample was a hot extruded chip under an extrusion ratio (ER) of 5.2 at an extrusion temperature of 500 °С (ET = 500 °C). The following results were obtained: grain size in ECAP-6 decreased from 15.9 to 2.46 μm, increasing both microhardness from 41 Vickers hardness value (HV) to 110 HV and ultimate tensile strength from 132.4 to 403 MPa. The largest decrease in surface roughness, Ra—70%, was obtained turning a workpiece treated with ECAP-6. The multicriteria optimization was computed in a multilayer perceptron-based artificial neural network that yielded the following optimum values: the minimal length of the three-dimensional estimates vector with the coordinates Ra = 0.800 μm, T_m = 0.341 min/cm³, and С = 6.955 $ corresponded to the optimal finish turning conditions: cutting speed v_c = 200 m/min, depth of cut a_p = 0.2 mm, and feed per revolution f_r = 0.103 mm/rev (ET-500 extrusion without hardening).

High-strength steels are used in various civilian and military products. The initial cost of the raw materials for these products is very high. The surface roughness of these products is extremely important during the finishing pass to be accepted during the final inspection. The surface roughness should conform to the required values stated on the design drawing. The paper presents the results of experiments in turning of high-strength steel featuring three factors—cutting speed V, feed rate f, and depth of cut t—on five levels (125 specimens). These were divided into 25 groups. Each of the five groups was subjected to one common machining speed. Each group was machined using five levels of cutting depth. Each depth was processed using five levels of feed rate. Tessa was used for examination of surface roughness. There is little modern research on machining high-strength steel. The high cost of this material compels us to look for the optimum turning conditions to provide for the specified roughness of surface Ra and the minimum machining time of unit volume T _m . As a result of our study, an artificial neural network was designed in Matlab on the basis of the MLP 3-10-1 multilayer perceptron that allows us to predict Ra of the workpiece with ±2.14% accuracy within the range of the experimental cutting speed, depth of cut, and feed rate values. For the first time, a Pareto frontier was obtained for Ra and T _m of the finished workpiece from high-strength steel using the artificial neural network model that was later used to determine the optimum cutting conditions. It is possible to integrate the suggested optimization algorithms into computer-aided manufacturing using Matlab.

Highly tensile manganese steel is in great demand owing to its high tensile strength under shock loads. All workpieces are produced through casting, because it is highly difficult to machine. The probabilistic aspects of its casting, its variable composition, and the different casting techniques must all be considered for the optimisation of its mechanical properties. A hybrid strategy is therefore proposed which combines decision trees and artificial neural networks (ANNs) for accurate and reliable prediction models for ore crushing plate lifetimes. The strategic blend of these two high-accuracy prediction models is used to generate simple decision trees which can reveal the main dataset features, thereby facilitating decision-making. Following a complexity analysis of a dataset with 450 different plates, the best model consisted of 9 different multilayer perceptrons, the inputs of which were only the Fe and Mn plate compositions. The model recorded a low root mean square error (RMSE) of only 0.0614 h for the lifetime of the plate: a very accurate result considering their varied lifetimes of between 746 and 6902 h in the dataset. Finally, the use of these models under real industrial conditions is presented in a heat map, namely a 2D representation of the main manufacturing process inputs with a colour scale which shows the predicted output, i.e. the expected lifetime of the manufactured plates. Thus, the hybrid strategy extracts core training dataset information in high-accuracy prediction models. This novel strategy merges the different capabilities of two families of machine-learning algorithms. It provides a high-accuracy industrial tool for the prediction of the full lifetime of highly tensile manganese steel plates. The results yielded a precision prediction of (RMSE of 0.061 h) for the full lifetime of (light, medium, and heavy) crusher plates manufactured with the three (experimental, classic, and highly efficient (new)) casting methods.