Modeling and Optimal Design of Machining-Induced Residual Stresses in Aluminium Alloys Using a Fast Hierarchical Multiobjective Optimization Algorithm

The residual stresses induced during shaping and machining play an important role in determining the integrity and durability of metal components. An important issue of producing safety critical components is to find the machining parameters that create compressive surface stresses or minimise tensile surface stresses. In this paper, a systematic data-driven fuzzy modelling methodology is proposed, which allows constructing transparent fuzzy models considering both accuracy and interpretability attributes of fuzzy systems. The new method employs a hierarchical optimisation structure to improve the modelling efficiency, where two learning mechanisms cooperate together: NSGA-II is used to improve the model’s structure while the gradient descent method is used to optimise the numerical parameters. This hybrid approach is then successfully applied to the problem that concerns the prediction of machining induced residual stresses in aerospace aluminium alloys. Based on the developed reliable prediction models, NSGA-II is further applied to the multi-objective optimal design of aluminium alloys in a ‘reverse-engineering’ fashion. It is revealed that the optimal machining regimes to minimise the residual stress and the machining cost simultaneously can be successfully located.