ANFIS based Model for Surface Roughness Prediction for Hard Turning with Minimal Cutting Fluid Application

In complex industrial processes (CIPs), due to technical and economic limitations, key performance indicators (KPIs), especially the chemical content-related KPIs, are often difficult to measure in real time, which hinders the propagation of advanced process control technologies. This paper presents a soft sensor-based online KPI inference scheme by a state transition algorithm (STA)-optimized adaptive pre-sparse neuro-fuzzy inference system model, called STA-APSNFIS. It introduces a pre-sparse neural network to the traditional adaptive neuro-fuzzy inference system (ANFIS) model to establish an adaptive pre-sparse neuro-fuzzy inference system (APSNFIS) model to alleviate the adverse effects of data redundancy and noise interference in the detectable process monitoring data, which can effectively reduce the complexity of neuro-fuzzy inference system (NFIS) and speed up its convergence. Successively, to avoid being trapped at a local optimum, the STA-based optimization algorithm is adopted to replace the traditional gradient-based optimization approach to achieve an optimal APSNFIS model. Extensive validation and comparative experiments on nonlinear numeric simulation systems, benchmark Tenessee Eastman (TE) process and a real industrial bauxite flotation process demonstrated that the proposed STA-APSNFIS performed favorably against traditional ANFIS model as well as its variants, e.g., PSO-ANFIS, GA-ANFIS, and some other soft sensor-based KPI inference models.

The blast furnace is a master iron-producing plant of iron and steel factories and affected by several process parameters as well as top gas pressure , which is a key process control phenomenon to maintain stability and operational productivity in such plants. Blast furnace operation is not tolerant to any interruption, unbalanced operations, momentary disturbances or loss of control due to its nature of intensive chemical reactions and heat balance requirements. Consequently, it is crucial to monitor and control top gas system components of the furnace with instrumentation measurements to maintain stable, efficient operation and system safety ongoing. In this study, a novel top gas pressure tracking system is developed using the chronologically obtained live process data of Erdemir BF#2 in Turkey. Eight process parameters are considered as input parameters as per the plant maintenance team's recommendations and soft computing methods, artificial neural networks and adaptive neuro fuzzy inference system are employed and a statistical regression tool, autoregressive integrated moving average, is also applied for comparison. Performance and success ratio analysis is carried out using coefficient of determination ( R2), mean absolute percentage error and root mean squared error terms. The best performing model output for the adaptive neuro fuzzy inference system is found to be 0.95, 1.21 and 0.023, and slightly lower performance is obtained for the artificial neural network model with the output values of 0.94, 0.029 and 1.32 against R2, mean absolute percentage error and root mean squared error terms, respectively. The maximum prediction error is found to be 9.85% and 10.2%, and the average prediction error is found to be 1.19% and 1.29% for adaptive neuro fuzzy inference system and ANN models, respectively, for optimum simulations. The proposed neuro-fuzzy-driven top gas pressure prediction system is unique in the literature and should be integrated into existing control systems to improve operational awareness and sustainability or can be used as input guidance for a possible future top gas recovery system.

This study describes a sensor system for continuous monitoring of volatile organic compounds (VOCs) emitted from small industrial facilities in urban centers, such as automobile paint facilities and printing facilities. Previously, intermittent measurements were made using expensive flame ionization detector (FID)-type instruments that were impossible to install, resulting in a lack of continuous management. This paper develops a low-cost sensor system for full-time management and consists of multi-sensor systems to increase the spatial resolution in the pipe. To improve the accuracy and reliability of this system, a new reinforced adaptive neuro fuzzy inference system (RANFIS) model with enhanced preprocessing based on the adaptive neuro fuzzy inference system (ANFIS) model is proposed. For this purpose, a smart sensor module consisting of low-cost metal oxide semiconductors (MOSs) and photo-ionization detectors (PIDs) is fabricated, and an operating controller is configured for real-time data acquisition, analysis, and evaluation. In the front part of the RANFIS, interquartile range (IQR) is used to remove outliers, and gradient analysis is used to detect and correct data with abnormal change rates to solve nonlinearities and outliers in sensor data. In the latter stage, the complex nonlinear relationship of the data was modeled using the ANFIS to reliably handle data uncertainty and noise. For practical verification, a toluene evaporation chamber with a sensor system for monitoring was built, and the results of real-time data sensing after training based on real data were compared and evaluated. As a result of applying the RANFIS model, the RMSE of the MQ135, MQ138, and PID-A15 sensors were 3.578, 11.594, and 4.837, respectively, which improved the performance by 87.1%, 25.9%, and 35.8% compared to the existing ANFIS. Therefore, the precision within 5% of the measurement results of the two experimentally verified sensors shows that the proposed RANFIS-based sensor system can be sufficiently applied in the field.

ERP projects’ failing to meet user expectations is a serious problem. This research develops an Adaptive Neuro Fuzzy Inference System (ANFIS) model, to predict the key ERP outcome “User Satisfaction” using causal factors present during an implementation as predictors. Data for training and testing the models was from a cross section of firms that had implemented ERPs. ANFIS is compared with other prediction techniques, ANN and MLRA. The results establish that ANFIS is able to predict outcome well with an error (RMSE) of 0.277 and outperforms ANN and MLRA with errors of 0.85 and 0.86 respectively. This study is expected to provide guidelines to managers and academia to predict ERP outcomes ex ante, and thereby enable corrective actions to redirect ailing projects.

The article focuses on developing a predictive and optimization model for surface roughness in ultra-precision turning (UPT) using a diamond cutter on the spherical surface of Al6061 material. An experimental model with 30 experiments was established, considering three input parameters: spindle speed, feed rate, and depth of cut. The results from this model were collected to create an input dataset for an artificial neural network (ANN) to build a surface roughness prediction model. The ANN structure 3-5-10-1 provided the best prediction results, with Coefficient of Determination ( ) is 0.98, Mean Absolute Percent Error ( ) is 13.36%, Mean Square Error ( ) is 0.68, and Root Mean Square Error ( ) is 0.82. Additionally, the artificial bee colony (ABC) algorithm was employed to determine the optimal cutting parameters that minimize surface roughness. The results indicated that the minimum roughness value achieved was 0.76 nm with the cutting parameters: spindle speed of 823 rev/min, feed rate of 13 mm/min, and depth of cut of 1 µm. Moreover, the effects of different cutting parameter combinations on surface roughness were analyzed and evaluated. The integration of the ANN model with the ABC algorithm enables a reliable prediction model for surface roughness and demonstrates high efficiency in optimizing the objective function. This research contributes valuable insights into surface roughness prediction and optimization in ultra-precision turning of Al6061 material. Furthermore, the proposed modeling and optimization approach can be extended to other materials and the processing of aspherical and diffractive surfaces.

LM 26 is a category of cast aluminum alloy which is having exceptional characteristics that leads to use of this alloy as primary choice for making automobile components. Metal matrix composite (MMC) materials are having improved characteristics and believed as an alternate for plentiful engineering industries. Due to reinforcement added, the materials became harder and result in inferior machining performance by traditional approaches. Wire electrical discharge machining (WEDM) is one among the advanced and also a conversant approach engaged for making intricate forms. In this exploration, an investigation on machinability of WEDM of stir-casted hybrid MMC (LM26+ Graphite+Fly ash) and evolution of hybrid adaptive neuro fuzzy inference system (ANFIS) model for predicting the desired variables. The ascendance of variables named as pulse on (Ton), pulse off (Toff), dielectric fluid flushing pressure, wire feed, and servo voltage in contrast to preferred output measures like material removal rate, surface finish, dimensional deviation, and form/orientation tolerance errors were investigated. A hybrid approach combining grey and ANFIS model has been developed to foretell the desired measures, and comparison has been done on the experimental and predicted results. The performance of the model is investigated and proved that the model can predict the desired measures.

In this paper, an approach in predicting surface roughness of Titanium Aluminum Nitrite (TiN) coatings using Adaptive Network Based Fuzzy Inference System (ANFIS) is implemented. The TiN coatings were coated on tungsten carbide (WC) using Physical Vapor Deposition (PVD) magnetron sputtering process. The N2 pressure, argon pressure and turntable speed were selected as the input parameters and the surface roughness as an output of the process. Response Surface Methodology (RSM) was used to design the matrix in collecting the experimental data. In the ANFIS structure, triangular, trapezoidal, bell and Gaussian shapes were used for as input membership function (MFs). The collected experimental data was used to train the ANFIS model. Then, the ANFIS model were validated with the actual testing data and compared with regression model in terms of the residual error and model accuracy. The result indicated that the ANFIS model using three bell shapes MFs obtained better result compared to the polynomial regression model. The number of MFs showed significant influence to the ANFIS model performance. The result also indicated that the limited experimental data could be used in training the ANFIS model and resulting accurate predictive result.

Using artificial neural network models and particle swarm optimization for manner prediction of a photovoltaic thermal nanofluid based collector

In this paper we have proposed an adaptive network based fuzzy inference system (ANFIS) model where the number of data pairs employed for training is minimized by application of two techniques called the full factorial design (FFD) and V-fold. Our proposed method is applied in building ANFIS models for the benchmark example of Box and Jenkins gas furnace data and the thermal power plant of the North Eastern Electrical Power Corporation Limited (NEEPCO). By employing our proposed method the number of data required for learning in the ANFIS network could be significantly reduced to around one-eighth of that required for the conventional ANFIS method. The results obtained by applying our proposed method are compared with those obtained by using conventional ANFIS network. It was found that our model compares favourably well with conventional ANFIS model

Polyethylene Terephthalate Glycol (PETG) is a fused deposition modeling (FDM)-compatible material gaining popularity due to its high strength and durability, lower shrinkage with less warping, better recyclability and safer and easier printing. FDM, however, suffers from the drawbacks of limited dimensional accuracy and a poor surface finish. This study describes a first effort to identify printing settings that will overcome these limitations for PETG printing. It aims to understand the influence of print speed, layer thickness, extrusion temperature and raster width on the dimensional errors and surface finish of FDM-printed PETG parts and perform multi-objective parametric optimization to identify optimal settings for high-quality printing. The experiments were performed as per the central composite rotatable design and statistical models were developed using response surface methodology (RSM), whose adequacy was verified using the analysis of variance (ANOVA) technique. Adaptive neuro fuzzy inference system (ANFIS) models were also developed for response prediction, having a root mean square error of not more than 0.83. For the minimization of surface roughness and dimensional errors, multi-objective optimization using a hybrid RSM and NSGA-II algorithm suggested the following optimal input parameters: print speed = 50 mm/s, layer thickness = 0.1 mm, extrusion temperature = 230 °C and raster width = 0.6 mm. After experimental validation, the predictive performance of the ANFIS (mean percentage error of 9.33%) was found to be superior to that of RSM (mean percentage error of 12.31%).

Surface roughness plays a major role in determining how an original component will interact with its environment. For getting a good surface finish, industries spent huge cost for introducing new technologies. The use of advanced engineering ceramics and composites in the aerospace and defence industries is continuous and increases day by day. Prediction of surface roughness plays a vital role in improving the surface finish in the industries. The present work deals with predicting the surface roughness (SR) of aluminium LM25 SiC 10% composite material in electrical discharge machining (EDM) using adaptive neuro-fuzzy inference system (ANFIS). The discharge voltage, discharge current, pulse on time, pulse off time, gap between tool and work piece and oil pressure are taken as the input parameters, whereas surface roughness is the output machining parameter. Design of experiment is based on Response Surface Methodology (RSM). ANFIS model has been constructed using Gaussian membership function (gaussmf) with two membership functions for each input variables and linear membership function for output. This paper uses the hybrid method for membership function parameter training. Based on the conclusion of ANFIS with hybrid method of membership function parameter training, it provides accurate results.

In this paper, a hybrid meta-heuristic artificial intelligence (AI) method, named “ANFIS–PSOGA,” is developed for modeling the discharge coefficient of circular side orifices for the first time. For this purpose, the adaptive neuro fuzzy inference system (ANFIS) network is optimized by means of two robust optimization algorithms: the genetic algorithm (GA) and the particle swarm optimization (PSO) algorithm. Furthermore, the Monte Carlo simulations are utilized to enhance the performance of the AI hybrid model. Besides, the k-fold cross-validation method is employed in order to verify the numerical results. Initially, the performance of three fuzzy inference system (FIS) generations of the ANFIS model including grid partitioning, subtractive clustering and fuzzy C-means clustering are evaluated. After that, using the parameters affecting the discharge coefficient, eleven ANFIS models are defined and then the best ANFIS model and the most influencing input parameters are identified through the conduction of a sensitivity analysis. For the superior ANFIS model, mean absolute percentage error, root-mean-square error and the correlation coefficient (R) are obtained 0.021, 0.020 and 0.871, respectively. Also, the Froude number (Fr) is detected as the most effective input parameter. Moreover, the discharge coefficient of the circular side orifices and the flow field within main channels along the side orifices are simulated through the adoption of a computational fluid dynamics (CFD) model. Additionally, the flow field at three different cross sections (beginning, middle and end of orifice) along the side weir is evaluated. For instance, by advancing the flow toward the side orifice, the Froude number is reduced. Besides, at each cross section, the maximum shear stress is estimated to occur in the vicinity of the crest of the circular side orifice. According to the CFD results, the maximum lateral velocity is estimated near the circular side orifice. In addition, the results yielded by the ANFIS, ANFIS–PSO, ANFIS–PSOGA and CFD models are compared and an uncertainty analysis is carried out for the models. Based on the comparison, ANFIS–PSOGA has the best performance in simulating the discharge coefficient. Ultimately, a simple and practical computer code for the best model (ANFIS–PSOGA) is proposed which can be easily used by scholars and engineers in practical usages.

Springback will occur when the external force is removed after bending process in sheet metal forming. This paper proposed an adaptive-network-based fuzzy inference system (ANFIS) model for prediction the springback angle of the SPCC material after U-bending. Three parameters were selected as the main factors of affecting the springback after bending, including the die clearance, the punch radius, and the die radius. The training data were obtained from results of U-bending experiment. The training data with four different membership functions – triangular, trapezoidal, bell, and Gaussian functions –were employed in the ANFIS to construct a predictive model for the springback of the U-bending. After the comparison of the predicted value with the checking data, we found that the triangular membership function has the best accuracy, which make it the best function to predict the springback angle of sheet metals after U-bending.

An empirical comparison of conventional techniques, neural networks and the three stage hybrid Adaptive Neuro Fuzzy Inference System (ANFIS) model for credit scoring analysis: The case of Turkish credit card data

An efficient and accurate prediction of a precise tidal level in estuaries and coastal areas is indispensable for the management and decision-making of human activity in the field wok of marine engineering. The variation of the tidal level is a time-varying process. The time-varying factors including interference from the external environment that cause the change of tides are fairly complicated. Furthermore, tidal variations are affected not only by periodic movement of celestial bodies but also by time-varying interference from the external environment. Consequently, for the efficient and precise tidal level prediction, a neuro-fuzzy hybrid technology based on the combination of harmonic analysis and adaptive network-based fuzzy inference system (ANFIS) model is utilized to construct a precise tidal level prediction system, which takes both advantages of the harmonic analysis method and the ANFIS network. The proposed prediction model is composed of two modules: the astronomical tide module caused by celestial bodies’ movement and the non-astronomical tide module caused by various meteorological and other environmental factors. To generate a fuzzy inference system (FIS) structure, three approaches which include grid partition (GP), fuzzy c-means (FCM) and sub-clustering (SC) are used in the ANFIS network constructing process. Furthermore, to obtain the optimal ANFIS based prediction model, large numbers of simulation experiments are implemented for each FIS generating approach. In this tidal prediction study, the optimal ANFIS model is used to predict the non-astronomical tide module, while the conventional harmonic analysis model is used to predict the astronomical tide module. The final prediction result is performed by combining the estimation outputs of the harmonious analysis model and the optimal ANFIS model. To demonstrate the applicability and capability of the proposed novel prediction model, measured tidal level samples of Fort Pulaski tidal station are selected as the testing database. Simulation and experimental results confirm that the proposed prediction approach can achieve precise predictions for the tidal level with high accuracy, satisfactory convergence and stability.