Ultrasonic Machining Process Optimization by Cuckoo Search and Chicken Swarm Optimization Algorithms

Ultrasonic Machining Process Optimization by Cuckoo Search and Chicken Swarm Optimization Algorithms

Bappa Acherjee (Department of Production Engineering, Birla Institute of Technology Mesra, Ranchi, India), Debanjan Maity (Department of Mechanical Engineering, IIT Kharagpur, Kharagpur, India) and Arunanshu S. Kuar (Department of Production Engineering, Jadavpur University, Kolkata, India)
Copyright: © 2020 |Pages: 26
DOI: 10.4018/IJAMC.2020040101
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The ultrasonic machining (USM) process has been analyzed in the present study to obtain the desired process responses by optimizing machining parameters using cuckoo search (CS) and chicken swarm optimization (CSO), two powerful nature-inspired, population and swarm-intelligence-based metaheuristic algorithms. The CS and CSO algorithms have been compared with other non-conventional optimization techniques in terms of optimal results, convergence, accuracy, and computational time. It is found that CS and CSO algorithms predict superior single and multi-objective optimization results than gravitational search algorithms (GSAs), genetic algorithms (GAs), particle swarm optimization (PSO) algorithms, ant colony optimization (ACO) algorithms and artificial bee colony (ABC) algorithms, and gives exactly the same results as predicted by the fireworks algorithm (FWA). The CS algorithm outperforms all other algorithms namely CSO, FWA, GSA, GA, PSO, ACO, and ABC algorithms in terms of mean computational time, whereas, the CSO algorithm outperforms all other algorithms except for the CS and GSA algorithms.
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1. Introduction

The development of the newer and harder materials is partly responsible for the advancement of machining technologies. The materials like ceramics, carbides, satellites, quartz, superalloys, etc., are used in many applications due to their several advantageous properties. These materials possess a very low machinability, and thus, producing complex shapes in those materials are extremely difficult with conventional machining processes. Sometimes producing a specific geometry is impossible to machine with the usual machining processes. In addition to that, the demand of higher production rate, dimensional accuracy and machining economy necessitate the use of unconventional or modern machining technologies.

Ultrasonic machining (USM) is a mechanical metal removal process for machining hard and brittle materials such as glass, ceramics, quartz, silicon etc., in which the material is removed from the workpiece surface due to brittle fracture caused by impact of abrasive grains because of tool vibrating at high frequency. Figure 1 shows a typical USM setup. The USM process starts with the conversion of low frequency electrical signal to a high frequency electrical signal, which is then fed to a transducer for getting converted to high frequency linear mechanical vibration. The vibration is then transmitted to the tool via tool holder. The tool made of ductile and tough material vibrates with high frequency and slurry of abrasive grains suspended in a liquid is fed into the cutting zone under pressure. The tool is gradually fed with uniform force. The impact from the tool propels the abrasive particles across the cutting gap, causing them to strike the workpiece (hammering and impact) which causes brittle fracture on workpiece surface, resulting in the removal of the material in the form of small wear particles which are carried away by the abrasive slurry.

Figure 1.

A typical ultrasonic machining setup


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