Research on Modeling and Optimization for Surface Roughness of Al6061 Spherical in Ultra-Precision Turning Based on Neural Network and Bee Colony Optimization Algorithm

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.