Cutting Parameters Optimization of Mild Steel via AIS Heuristics Algorithm

. The minimum cost and high productivity of the recent industrial renaissance are its main challengers. Selecting the optimum cutting parameters play a significant role in achieving these aims. Heat generated in the cutting zone area is an important factor affecting workpiece and cutting tool properties. The surface finish quality specifies product success and integrity. In this paper, the temperature generated in the cutting zone (shear zone and chip-tool interface zone) and workpiece surface roughness is optimized using an artificial immune system (AIS) intelligent algorithm. A mild steel type (S45C) workpiece and a tungsten insert cutting tool type (SPG 422) is subjected to dry CNC turning operation are used in experiments. Optimum cutting parameters (cutting velocity, depth of cut, and feed rate) calculated by the (AIS) algorithm are used to obtain the simulated and ideal cutting temperature and surface roughness. An infrared camera type (Flir E60) is used for temperature measurement, and a portable surface roughness device is used for roughness measurement. Experimental results show that the ideal cutting temperature (110°C) and surface roughness (0.49 μm) occur at (0.3 mm) cut depth, (0.06 mm) feed rate, and (60 m/min) cutting velocity. The AIS accuracy rates in finding the ideal cutting temperature and surface roughness are (91.70 %) and (90.37 %) respectively. Analysis shows that the predicted results are close to the experimental ones, indicating that this intelligent system can be used to estimate cutting temperature and surface roughness during the turning operation of mild steel.