Analytical approach-based optimization of the actively driven rotary turning for environmental and economic metrics considering energy footprint of materials

The current work has been performed an effective optimization to decrease the total energy consumption (Etotal) and total machining time (Ttotal) with the constraint of the average roughness for the actively driven rotary turning (ADRT) of the material labeled SKD11. The optimizing factors are the tool rotational speed (vt), depth of cut (a), feed rate (f), and workpiece speed (vw). The analytical approach was used to construct the models of the Etotal and Ttotal. The weightage principal component analysis (WPCA) was applied in conjunction with the non-dominated sorting particle swarm optimization (NSPSO) and the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) to determine the weight values of machining responses and select the best optimal solution. The scientific findings revealed that the optimal values of the vt, a, f, and vw were 78 m/min, 0.21 mm, 0.44 mm/rev., and 98 m/min, respectively. The reductions in the Etotal and Ttotal were 16.99% and 17.78%, respectively. Moreover, the proposed models of the Etotal and Ttotal were significant and could be used to predict technical performances with acceptable accuracy. The optimization technique comprising the analytical method, NSPSO, WPCA, and TOPSIS was named as a powerful approach to obtain optimal outcomes. © 2021, The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature.