Single Row Facility Layout Problems, Manufacturing Optimization
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Scopus Publications
Scopus Publications
Machine learning–assisted evolutionary optimization of hole quality and surface integrity in abrasive waterjet drilling of polycarbonate J. Bharani Chandar, C. Rathinasuriyan, N. Lenin, M. Sivakumar, Robert Čep, Sachin Salunkhe Scientific Reports, 2026 Abrasive Waterjet Machining (AWJM) is a reliable non-traditional technology for machining polymer-based engineered materials with low thermal degradation, dimensional inaccuracy, and surface damage. This study examines polycarbonate hole drilling performance using 125 full-factorial experimental trials using process parameters water pressure, standoff distance, and traverse rate. With a coordinate measuring machine and stylus-based profilometer, kerf angle, entry and exit circularity, and surface roughness were measured in a detailed metrological research. Four ML models were created to develop accurate predicting capabilities, with the Random Forest (RF) model performing best in all responses. RF predicted processes accurately with high coefficient-of-determination R 2 values (0.92, 0.82, 0.82, and 0.92) and low error coefficients (RMSE 0.196, 0.045, 0.042, and 0.452). The best drilling settings were found using evolutionary algorithms like Biogeography-Based Optimization (BBO), Particle Swarm Optimization (PSO), Salp Swarm Optimization (SSO), and Tug-of-War Optimization (TWO). Deng’s similarity metric ranked SSO as the best optimizer based on many responses. The SSO produced the optimal settings (W p = 250 MPa, S d = 1.5, and T r = 300 mm/min) for reduced kerf deviation, circularity and surface roughness. Under optimal circumstances, anticipated responses matched experimental results, proving the integrated ML-optimization framework’s strength.
A novel predictive model for abrasive waterjet deep hole drilling on AL7075 T6 using machine learning and evolutionary algorithmic approach J. Bharani Chandar, M. Sivakumar, N. Lenin, Robert Čep, Sachin Salunkhe, Emad Abouel Nasr, C. Rathinasuriyan Scientific Reports, 2025 Abrasive Waterjet (AWJ) is a promising non-traditional method for precision cutting of aerospace materials like AL7075 T6. This work explores AL7075 T6 AWJ-based Deep Hole Drilling (DHD) using a full factorial design with accurate modeling and optimization performed through machine learning and evolutionary algorithms. The objective is to investigate the influence of process parameters and to model, and predict the optimal AWJ-DHD settings, such as waterjet pressure, standoff distance, and abrasive mass flow rate, on drilling qualities including geometrical and dimensional precision (kerf angle, kerf ratio), surface roughness, and drilling efficiency. Four machine learning models, Adaptive Boosted Regression (ABR), Extreme Gradient Boosting (XGB), Decision Tree (DT), and Random Forest (RF) were developed with experimental data to enhance prediction accuracy and process efficiency. Among the developed models, RF had the lowest testing error value for all responses with root mean square values of 0.046 (kerf angle), 0.0078 (kerf ratio), 0.044 (surface roughness), and 0.027 (drilling rate). Moth-Flame Optimization (MFO), Differential Evolution (DE), and Sine Cosine Algorithm (SCA) were used for multi-response optimization of AWJ deep hole drilling parameters. The optimal algorithm for each response was selected using Deng's similarity-based ranking. The ranking revealed SCA algorithm outperformed MFO and DE. The SCA algorithm discovered optimal parameter setting for AWJ-DHD as a water pressure of 350 MPa, standoff distance of 1.5 mm, and an abrasive mass flow rate of 300 g/min. Under these conditions, the predicted responses were a kerf angle of 0.048⁰, kerf ratio of 0.011, a surface roughness of 1.438 μm, and a drilling rate 0.769 mm/s. The validation trials using optimized parameters yielded a kerf angle of 0.047⁰, a kerf ratio of 0.066, a surface roughness of 1.40 μm, and a drilling rate of 0.769 mm/s, with percentage variations of 2.08%, 3.03%, 2.14%, and 2.65%, respectively, thereby demonstrating the efficiency of the developed machine learning model and optimization technique. The integrated machine learning and evolutionary algorithm framework improved drilling efficiency and hole quality by minimizing surface roughness.
Process parameter optimization for minimizing overcut in abrasive waterjet deep hole drilling of SS 316L J. Bharani Chandar, N. Lenin, Alagar Karthick, Pradeep Kumar Singh, M. Siva Kumar, Md Irfanul Haque Siddiqui, Intesaaf Ashraf, Saurav Dixit, Nikolai Ivanovich Vatin, Choon Kit Chan Scientific Reports, 2025 The need for precise manufacturing in aerospace, medical, and automotive industries requires an investigation of upscale drilling methods that can achieve small-diameter deep holes with exceptional accuracy. Abrasive Waterjet Drilling (AWJD) has developed as a promising technology due to its distinctive blend of precision and adaptability. Despite several advantages, overcutting is the fundamental obstacle restricting the widespread use of AWJD. The novelty of this research is to investigate the impact of process parameters, specifically water pressure, standoff distance, and abrasive mass flow rate, on the top, bottom, and depth-averaged radial overcut developed during the deep hole drilling of stainless steel 316L material. The deep hole drilling experiments have been conducted utilizing Taguchi’s (L 16 ) orthogonal array by adjusting the drilling settings. The statistical significance of specific drilling parameters and second-order quadratic models for the responses have been established by analysis of variance. Additionally, to mitigate the impact of overcut and improve the drilling quality necessary for diverse sectors such as automotive, biomedical, and oil and gas, a metaheuristic optimization method, specifically the Grasshopper Optimization Algorithm (GHO), has been utilized. Thereafter, the effectiveness of the suggested algorithm has been validated using quality measures, namely hyper-volume and spacing by comparing it to the approaches of whale optimization, harmony search, and multiverse optimization algorithms. The comparison shows that the GHO algorithm outperformed the others. The GHO algorithm identified the optimal process parameters for AWJD as water pressure 305.36 MPa, standoff distance 1.00 mm, and mass flow rate 600 g/min. The anticipated values for the top, bottom, and depth-averaged radial overcut, according to the optimal parameters, are 1.19 mm, 0.64 mm, and 1.53 mm, respectively. Furthermore, a validation test has been conducted to verify the efficacy of the GHO algorithm. The validation test showed top, bottom, and depth-averaged radial overcut values of 1.17 mm, 0.66 mm, and 1.49 mm, with percentage deviations of 1.71%, 3.03%, and 2.68%, respectively, with the GHO algorithm. The surface quality of the drilled holes has been examined through a Scanning Electron Microscope (SEM). The SEM images have been obtained at magnifications of 12X and 500X of the drilled hole surface using optimum parameters, demonstrating smooth and uniform surfaces at the top, middle, and bottom of the drilled hole.
UNRAVELING THE MACHINABILITY OF NIMONIC 263: AN EXPERIMENTAL STUDY USING ABRASIVE WATERJET CUTTING DEEPAK CHANDRAN GANESH, LENIN NAGARAJAN, BALAJI VASUDEVAN Surface Review and Letters, 2025 The demand for high-performance materials in aerospace, automotive, and power generation industries has led to the development and utilization of advanced superalloys. Nimonic C-263/263, a nickel-based superalloy, is widely employed in critical components of jet engines, such as combustion chambers, heat exchangers, reformer tubes, gas turbine power generation components like turbine discs, shafts, and blades, due to its exceptional high-temperature strength, corrosion resistance, and creep properties. However, the inherent hardness and toughness of this alloy pose significant challenges for conventional machining processes. Abrasive waterjet cutting (AWJC) emerges as a promising alternative for the efficient machining of such difficult-to-cut superalloy materials. This paper presents an in-depth investigation on the machinability of thick Nimonic 263 superalloy plate material using AWJC, aiming to provide insights into the effects of process parameters, cutting performances, and resulting surface integrity due to change in declination angle measurement. An examination was also conducted on the pattern of striation formation under varying process parameters, utilizing digital microscopic images. The goal of the study is to establish a link between the parameters of striation production and the angle of jet impingement. The results indicate that a decrease in striation during the water jet processing of Nimonic 263 superalloy is caused by an increase in the declination angle.
Performance assessment of different cooling conditions in the sustainable machining of Hastelloy X alloy Xiaoming Huang, Qian Zhou, Sivakumar Mahalingam, Lenin Nagarajan, Poongavanam Ganesh Kumar, Vinothkumar Sivalingam Proceedings of the Institution of Mechanical Engineers Part E Journal of Process Mechanical Engineering, 2025 The primary goal of this study is to explore techniques that can enhance the machinability of Hastelloy X under different cooling conditions. L27 orthogonal turning experiments were performed with process parameters such as cutting speed ( vc), feed rate ( f) and depth of cut ( ap) to study the effect of tool wear and machining cost. The control parameters of a procedure were evaluated through a multiple linear regression model (MLRM) derived from the correlation between the output responses and the input parameters. A multi-verse optimisation algorithm (MVO) was proposed for optimisation studies. It achieves this by minimising the tool wear and machining cost. The proposed algorithm was evaluated against the techniques used for particle swarm and salp swarm optimisations. According to the study, the MVO algorithm outperformed other methods to identify the optimal control parameters for a given process. Based on the analysis, the anticipated tool wear duration is 17.57 min, and the machining cost is estimated at 0.934 $/cm3 under cryogenic conditions. Cryogenic cooling reduces chipping and adhesion in cutting by minimising workpiece softening and improving cutting tool hardness.