The present paper deals with the development of prediction model using response surface methodology and artificial neural network and optimizes the process parameter using 3D surface plot. The experiment has been conducted using coated carbide insert in machining AISI 1040 steel under dry environment. The coefficient of determination value for RSM model is found to be high (R2 = 0.99 close to unity). It indicates the goodness of fit for the model and high significance of the model. The percentage of error for RSM model is found to be only from -2.63 to 2.47. The maximum error between ANN model and experimental lies between -1.27 and 0.02 %, which is significantly less than the RSM model. Hence, both the proposed RSM and ANN prediction model sufficiently predict the surface roughness, accurately. However, ANN prediction model seems to be better compared with RSM model. From the 3D surface plots, the optimal parametric combination for the lowest surface roughness is d1-f1-v3 i.e. depth of cut of 0.1 mm, feed of 0.04 mm/rev and cutting speed of 260 m/min respectively.

Enhancing the overall machining performance implies optimization of machining processes, i.e. determination of optimal machining parameters combination. Optimization of machining processes is an active field of research where different optimization methods are being used to determine an optimal combination of different machining parameters. In this paper, multi-stage Monte Carlo (MC) method was employed to determine optimal combinations of machining parameters for six machining processes, i.e. drilling, turning, turn-milling, abrasive waterjet machining, electrochemical discharge machining and electrochemical micromachining. Optimization solutions obtained by using multi-stage MC method were compared with the optimization solutions of past researchers obtained by using meta-heuristic optimization methods, e.g. genetic algorithm, simulated annealing algorithm, artificial bee colony algorithm and teaching learning based optimization algorithm. The obtained results prove the applicability and suitability of the multi-stage MC method for solving machining optimization problems with up to four independent variables. Specific features, merits and drawbacks of the MC method were also discussed.

Optimization of machining processes not only increases machining efficiency and economics, but also the end product quality. In recent years, among the traditional optimization methods, stochastic direct search optimization methods such as meta-heuristic algorithms are being increasingly applied for solving machining optimization problems. Their ability to deal with complex, multi-dimensional and ill-behaved optimization problems made them the preferred optimization tool by most researchers and practitioners. This paper introduces the use of pattern search (PS) algorithm, as a deterministic direct search optimization method, for solving machining optimization problems. To analyze the applicability and performance of the PS algorithm, six case studies of machining optimization problems, both single and multi-objective, were considered. The PS algorithm was employed to determine optimal combinations of machining parameters for different machining processes such as abrasive waterjet machining, turning, turn-milling, drilling, electrical discharge machining and wire electrical discharge machining. In each case study the optimization solutions obtained by the PS algorithm were compared with the optimization solutions that had been determined by past researchers using meta-heuristic algorithms. Analysis of obtained optimization results indicates that the PS algorithm is very applicable for solving machining optimization problems showing good competitive potential against stochastic direct search methods such as meta-heuristic algorithms. Specific features and merits of the PS algorithm were also discussed.

Ti-6Al-4V Extra Low Interstitial (ELI) exhibits superior properties because of controlled interstitial element of iron and oxygen. The effects of four cutting parameters namely cutting speed, feed, depth of cut and tool nose radius on responses like cutting force, average cutting temperature and surface roughness have been investigated for turning of Ti-6Al-4V (ELI). Total 81 experiments have been performed in dry environment. Grey Relational Analysis has been used for multi-objective optimization. Analysis of Variance test has been carried out to investigate contribution of input parameters. The model was found fit with R-Square value of 88.74%. Regression and ANN models are developed for prediction and compared. From the Grey relational analysis, it is clear that optimum parameters to minimize cutting force, cutting temperature and surface roughness while turning Ti-6Al-4V (ELI), are cutting speed as 140 rpm, Nose radius 1.2mm, Feed 0.051mm/rev and depth of cut is 0.5mm. In comparison of regression model, the ANN model is found to be more accurate with average error of 3.57%.