International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 INTERNATIONAL JOURNAL OF MECHANICAL 6340(Print), ISSN 0976

6 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME

ENGINEERING AND TECHNOLOGY (IJMET)

ISSN 0976 6340 (Print) ISSN 0976 6359 (Online) Volume 3, Issue 2, May-August (2012), pp. 128-137 IAEME: www.iaeme.com/ijmet.html Journal Impact Factor (2011): 1.2083 (Calculated by GISI) www.jifactor.com

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MATERIAL REMOVAL RATE PREDICTION OF C-SIC COMPOSITE: COMPARATIVE ANALYSIS OF NEURAL NETWORK AND FUZZY LOGIC
Pallavi.H.Agarwal1 , Prof.Dr.P.M.George 2 and Prof.Dr.L.M.Manocha 3 Research Scholar, Sardar Patel University, Vallabh Vidyanagar, Gujarat pallavi_ruhi@yahoo.co.in 2 Professor (Mechanical), B.V.M.Engineering College, Vallabh Vidyanagar, Gujarat 3 Professor (Material Science), Sardar Patel University, Vallabh Vidyanagar, Gujarat
1

ABSTRACT Material removal rate is an important objective function in manufacturing engineering. It holds the characteristic that is can influence the performance of mechanical parts, which is proportional to manufacturing cost. MRR (material removal rate) is also an aspect for designing mechanical elements. Material removal rate is an essential feature of drilling operation since most of the holes applications are required for assembly work. The aim of this experimental and analytical research is to identify the parameters which enable the prediction of MRR in drilling. Two expert systems are used to analyze the best fit model in predicting the MRR for this specific drill job on C-SiC composite. The prediction accuracy is then compared to analyze which model could give better results so that it can be recommended for machine learning and also future work. It is found that BPN-ANN gives better and closer values as compared to the Sugeno ANN model. Keywords Artificial neural network (ANN), Sugeno fuzzy, fuzzy logic, material removal rate (MRR), automatic tool changer (ATC), Back propagation network (BPN)

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME

1. INTRODUCTION In the investigation of drilling of C-SiC, the MRR is considered essential as it influences the surface finish and the micro geometry of the finished part. Optimum selection of the process conditions is extremely important as it determines the MRR which in turn affects the surface finish of the machined parts. Thus in this drilling process an improper selection of cutting conditions can lead to surfaces with rough finish. The resurgence of interest in expert systems over the past few decades has opened many new avenues in various applications. Expert systems lead to greater generality and better rapport with reality. It is driven by the need for methods of analysis and design, which can come to grips with imprecision to achieve robustness and low cost production solution [2]. The use of neural network in machining research has been extensive and multifaceted. These networks can be trained to recognize arbitrary relations between sets of inputs and output pairs by adjusting weights of the interconnections. Back propagation neural network is most commonly used in manufacturing research and neural network has been used extensively in the past decade to monitor the progress of tool condition. Fuzzy modeling is based on the idea to find a set of local input-output relations describing a process. So, the method of fuzzy modeling can express a nonlinear process better than any other ordinary method. As more knowledge about the system is accumulated the uncertainty diminishes the need for the fuzzy logic treatment and it can revert to a deterministic or statistical one. The aim of this experimental and analytical work is to identify suitable parameters, the monitoring of which enable the prediction of MRR for drilled holes by two expert systems namely Sugeno-Fuzzy and Neural network. Both have their own ability in determining the output which determines and maintains the quality of drilled surface. Finally the best expert system has to be recommended for this drilling job on carbon silicon carbide composite as per their limitations and advantages by carrying out comparative analysis among the expert systems within the range of experimental values. 2. EXPERIMENTAL PROCEDURE The work piece material used is carbon silicon carbide composite .The machine used is Den ford CNC machine with Fanuc controller. The VMC has a maximum cross travel of 170 mm, maximum long travel of 290 mm and head travel of 235 mm with a six station ATC. The spindle speed range available is 0-4000 rpm and the feed range available is 0-1000 mm/min. Factorial approach [16] which is very effective to deal with responses influenced by multi variables is used to conduct the experiments. This method is a powerful design of experiment tool, which provides a simple, effective and systematic approach to experimentation. This method reduces the number of experiments that are required to model the response functions. Traditional experimentation is one factor at a time experiment, where one variable is changed while the rest are held constant. The major disadvantage of traditional experimentation is that it fails to consider any possible interactions between the parameters. An interaction is the failure of one factor to produce the same effect on the response at different levels of another factor. The factorial design approach has many advantages. It allows the interactions to be evaluated so that misleading conclusions can be
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME

avoided. This approach also allows the effects of a factor to be estimated at several levels of the other factors, yielding conclusions that are valid over a range of experimental conditions. It is also impossible to study all the factors and determine their main effects in a single experiment. The machining parameters used are as shown in Table 1. The experiments are planned according to 23 with 4 center points. The design matrix with the response parameter MRR is as shown in Table 2. Table 1: Machining parameters and their levels Sample A B C Machining Parameters Spindle speed Feed rate Drill size Unit Rpm mm/min Mm -1 1500 30 1 0 2250 35 2 1 3000 40 3

Table 2: Design Matrix with response parameter MRR Experiment No 1 2 3 4 5 6 7 8 9 10 11 12 A + + + + 0 0 0 0 Factors B + + + + 0 0 0 0 MRR(g) C + + + + 0 0 0 0 0.0145 0.0159 0.0132 0.0248 0.0222 0.0003 0.0004 0.0529 0.0206 0.0482 0.0141 0.0003

3. EXPERT SYSTEMS A. Artificial Neural Network Recent research activities in artificial neural networks (ANNs) have shown that ANNs have powerful pattern recognition and classification. ANNs are suited for problems which require knowledge that is difficult to specify but for which there are enough data or observations. They learn from the training data and capture information about relationships among the data even if underlying relationships are unknown or hard to
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME

describe. ANNs are universal approximations [3] it has been shown that a network can approximate any continuous function to any desired accuracy by many researchers [4], [5]. Neural network which uses back propagation algorithms for modeling has been developed using machining process parameters, spindle speed, feed rate and drill size as input parameters and material removal rate as output parameter. Making connections from the input layer to the output layer improves the learning efficiency. Out of the experimental data generated, the training data is used to train the model and this data is not used for testing and validation. The BP algorithm was developed by Paul Werbos in 1974 and rediscovered by Rumelhart and Parket. Since its rediscovery, the back propagation algorithm has been widely used as a learning algorithm in the feed forward multilayer neural network. The back propagation algorithm is applied to feed forward ANNs with one or more number of hidden layers as shown in Fig.1.Based on this algorithm, the network learns a distributed associative mapping between the input and output layers. What makes this algorithm different than the others is the process by which weights are calculated during the learning phase of the network. The input layer is used to feed the data in the network. The inputs are subsequently modified based on the interconnection weights between layers. The net input to each neuron from the preceding layer will be as:
N

netj= wi jx i + b j
i =1

Fig.1 Feed Forward Multilayer Perceptron Where, netj is the net input, N is the number of neurons of the inputs to the jth neuron in the hidden layer. Wij is the interconnected weight from the ith neuron in the forward layer to the jth neuron in the hidden layer, xi is the input from the ith neuron in the hidden layer and bj is the bias value corresponding to the neuron. The output signal is obtained by applying activations to the net input. In this particular analysis, multilayer back propagation neural network model is developed using MATLAB neural network toolbox for predicting the material removal rate in drilling C/SiC material. There is one input vector with three elements. The value of the first element of the input vector ranges between 1500 to 3000 rpm, the values of the second element of the input vector ranges between 30-40 mm/min and the value of the third element of the input vector ranges between 1-3 mm. There are twenty neurons in the hidden layer and one neuron in the output layer. The number of neurons in the hidden layer was chosen based on the MSE value which is least between 20 to 25 nodes as shown in Fig.2

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME

The transfer function in the hidden layer and the output layer is tan-sigmoid. The training function is trainlm which updates weight and the bias values according to the Levenberg-Marquadrt optimization rule.

Fig 2 Effect of number of nodes in the hidden layer Network learning function is learngdm which is the gradient descent with momentum weight and bias learning function. The data is divided as training data to train the neural network. The testing data is used to test the model; it does not take part in the training of the model. The mean squared error (MSE) is the criterion for selecting the network structure. Here the error is calculated as the difference between the target output and the network output The experimental data is used to train and validate the ANN. The prediction of the MRR by neural network is shown in Table 3. B.FUZZY SYSTEM Fuzzy logic has lot of application in the real world. Basically the system will accept the input or some inputs and pass the inputs to a process called fuzzification. In the fuzzification process, the input data will undergo some translation into the linguistic quantity as low, medium, high of the physical properties. The translated data will be sent to an inference mechanism that will apply the predefined rules. The inference engine generates the results in the linguistic form. The linguistic output will go through defuzzification process to be in numerical form. Defuzzification is defined as the conversion of a fuzzy membership function to precise or crisp quantity [9], [10]. Fuzzy modeling and approximation are the most interesting fields where the fuzzy theory can be effectively applied. As far as modeling and approximation is concerned one can say that the main interest is towards the applications when we intend to apply fuzzy modeling and approximation to an industrial process. One of the key problems to be solved is to find the fuzzy rules. Sugeno Type fuzzy inference The most commonly known or used fuzzy inference methodology is Mamdani. But this paper discussed the Sugeno or Takagi-Sugeno-Kang, method of fuzzy inference. The main difference between Mamdani and Sugeno is that the Sugeno output membership functions are either linear or constant but can be excellently suited for modeling nonlinear systems by interpolating between multiple linear models. A typical rule in a Sugeno fuzzy model has the form: If Input 1=x, Input 2=y, then output z=ax+by+c.
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For a zero order Sugeno model, The output level Z is a constant (a=b=0). The output level Zi of each rule is weighted by the firing strength Wi of the rule. For example, for an AND rule with Input 1=x and Input 2=y the firing strength is Wi= and method [F1(x), F2(y)] Where F1 and F2 are the membership functions for the input 1 and 2, the final output of the system is the weighted average of all rule outputs, computed as shown by equation stated below and the Sugeno rule operates as shown in Figure 3 Final Output = ( )/( )

Fig.3 Sugeno-Fuzzy Output Rule Due to linear dependence of each rule on the input variables of the system, the Sugeno method is ideal for acting as an interpolating supervisor of multiple linear controllers that are to be applied, respectively, to different operating conditions of a dynamic nonlinear system. A Sugeno fuzzy inference system is extremely well suited to the task of smoothly interpolating the linear gains that would be applied across the input space, it is a natural and efficient gain scheduler. A Sugeno system is well suited for modeling nonlinear systems by interpolating between multiple linear models [10]. The plot of membership functions and the input-output variables fed into the Fuzzy Inference System [FIS] is shown in Figure 4, where L,M and H denotes Low, Medium and High respectively.

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Fig.4 Membership function of Sugeno-Fuzzy Upon developing the membership function, precise rules have been fed into the system relating the FIS input-output variables. Each of these rules plays an important role in generating the fuzzy logic controller model and the accuracy of the numerical output. Upon the rules determination, the fuzzy logic controller will simulate the FIS variables with respective rules and modeling of the controller toolbox will take place. The model controller toolbox to the system is shown in the Figure 5.

Fig.5 Controller tool box for each rule. 4. RESULTS AND DISCUSSION Fig. 6 and 7 are the Sugeno-Fuzzy based surface model showing an excellent relationship between the two sets of input variables: speed and feed rate and drill size. Fig.6 with the output material removal rate plotted against speed and feed rate and in the Fig.7 the output material removal rate is plotted against speed and drill size. The

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inference drawn is that for medium feed rate, drill size and spindle speed the MRR rate is higher for carbon silicon carbide composite.

Fig.6 Sugeno Fuzzy model (spindle speed & feed rate)

Fig.7 Sugeno Fuzzy model (spindle speed & drill size)

Fig. 8 Sugeno Fuzzy model(spindle speed and drill size)

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME

Table 3 Output Result Table Experiment Actual MRR Predicted MRR(BPN) Error(BPN) Fuzzy MRR Error(fuzzy) 1 0.0222 0.0282 -0.0065 0.0010 0.0212 2 0.0529 0.0205 -0.0323 0.0025 0.0504 3 0.0482 0.0206 -0.0276 0.0206 0.0276

From the numerical data, it is clear that the BPN system has produced closer output as compared to Sugeno-fuzzy system. It has been studied that Fuzzy has the ability of predicting the future (forecasting) based on the membership function of the input and the output variables, limits and rules fed. Although its values are not the best, but it also matches closely to the actual. 5. CONCLUSION BPN has shown the capability of generalization and prediction of material removal rate in drilling within the range of experimental data. The maximum deviation observed and estimated by BPN is minimal. The present work can be extended with different process parameters, material thickness and type to test the ability of the expert systems in prediction of the output and these findings can then be applied to indirect tool condition monitoring in unmanned manufacturing system. The predicted values of the ANN output can be further improved by increasing the weights of the experiments.

6. ACKNOWLEDGEMENTS I am thankful to Mr.Sreeram R. who introduced me to the domain of fuzzy logic and neural network. 7. REFERENCES [1] Rot Berg and Ber, Methods for drilling parameters evaluation applied for drill point development , Annals of CIRP, vol. 36, pp.49-51, 1997. [2] Matsumura T. and Obikawa T, On the development of expert system for selecting the optimum cutting , Journal of the Japan Society of Precision Engineering, 58, pp.1691-1696, 1992.

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[3] Kuo. R.J.,Intelligent tool wear system through artificial neural networks and fuzzy modelling , Journal of Artificial Intelligence in Engineering, 5, pp.229-242, 1998. [4] Choudhury S.K. and Jain V.K., Online monitoring of tool wear in turning using a neural network , International Journal of Machine tools and Manufacturing, 39, pp.489504, 1999. [5]Rahaman M, and Zhou Q, Online cutting state recognition using a neural network,International Journal of Advanced Manufacturing Technology, vol.2, pp.8792, 1995. [6] Eshima T and Shibasaka,Estimation of cutting tool life by processing tool images data with neural network, CIRP Annals, vol.42, pp.59-62, 1993. [7] Rangwala.S, and Dornfeld, Sensor integration using neural networks for intelligent tool condition monitoring,ASME Journal of Engineering and Industry, 112, pp.219228, 1990. [8] Masory, Monitoring machining processes using multisensory readings fused by artificial neural networks , 7th International Conference on Computer aided production Engineering, vol.28, pp.231-240, 1991. [9] Li.P.G. and S.M.Wu,Monitoring drilling wear states by a fuzzy pattern recognition technique, Journal of Engineering for Industry, 110, pp.297-302, 1998.

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