OPTIMIZING THE SURFACE ROUNDNESS OF INCONEL 625 TUBES USING CHEMICALLY ASSISTED MAGNETIC ABRASIVE FINISHING WITH A GENETIC ALGORITHM

Inconel alloy is becoming increasingly popular for use in complex constructions in the aerospace, marine, and automotive industries because of its exceptional qualities. Therefore, there is a wide scope for improving the geometrical accuracy with precise surface finish of Inconel 625 tubing used in these industries. To enhance the surface roundness with precise surface finish, the process optimization is required. In the present work, Genetic Algorithm (GA)-driven multi-objective optimization of chemically assisted magnetic abrasive finishing (CMAF) for internal and external roundness of Inconel 625 tubes has been attempted. Experiments were conducted as per Response Surface Methodology (RSM). Regression models were generated to attain the GA objectives for percentage improvement in internal roundness (PIIR) and percentage improvement in external roundness (PIER). GA-driven multi-objective optimization recommended the best optimal parametric setting at 75[Formula: see text]min (processing time), 60 RPM (surface rotational speed), 34.28% (weight %age of abrasives), 500[Formula: see text]gm/lt. (chemical concentration), and 32.22[Formula: see text] [Formula: see text]m (abrasive size) for PIER and PIIR. The confirmation tests performed under the optimal parameters show that the average PIIR and PIER are 40% and 32%, respectively, and the average PIISF and PIESF are 70% and 65%, respectively. Scanning Electron Microscopy (SEM) analysis also revealed that surface texture gets improved using the optimal conditions, resulting in an improvement in surface roundness of Inconel 625 tubes.