An Energy Efficient Turning Process for Hardened Material with Multi-criteria Optimization

This paper presents a systematic procedure for the optimization of machining parameters such as cutting speed, feed rate, nose radius, edge radius, and rake angle to reduce specific material removal energy and improve energy efficiency in the hard turning of AISI 4140 steel. A simulation approach was applied in conjunction with the design of experiment (DOE), mathematical approximation with a meta-model to develop specific energy as well as an energy efficiency model in terms of cutting parameters. A hybrid approach that combines the Multi-Objective Particle Swarm Optimization (MOPSO) and the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) using entropy weights was adopted to determine the best solution from the Pareto set. The results showed that energy efficiency could be improved by 11%, whereas specific energy decreased by approximately 15% compared to a non-optimal case. Therefore, this study is expected as a contribution to making the turning process of hardened materials greener and more efficient.