Performance evaluation of machine learning algorithms in predicting machining responses of superalloys

This study explores the application of machine learning algorithms—gene expression programming (GEP), adaptive neuro-fuzzy inference system (ANFIS), and artificial neural networks (ANN)—to predict machining responses during the milling of Inconel 690, a superalloy known for its exceptional mechanical properties and oxidation resistance. Machining Inconel 690 presents significant challenges due to its toughness and work-hardening tendencies, which can lead to rapid tool wear and poor surface finish. Traditional optimization methods often rely on empirical models and trial-and-error approaches, which are time-consuming and costly. In contrast, machine learning techniques can effectively model complex, nonlinear relationships between machining parameters and performance outcomes, such as surface roughness, cutting force, and cutting temperature. This study employs statistical metrics, including Root mean square error (RMSE), coefficient of determination (R2), and mean absolute percentage error (MAPE), to determine the predictive performance of the models. The results show that the GEP model achieved an R2 ranging from 0.944 572 to 0.992 999, with an RMSE between 0.015 527% and 0.694 523% and a MAPE ranging from 1.452 397% to 4.947 892%. ANFIS and ANN also demonstrated strong predictive capabilities, although GEP outperformed them. The importance of this study lies in its demonstration of advanced AI techniques as effective tools for optimizing machining processes, ultimately contributing to improved efficiency and quality in manufacturing superalloys.