Multi-responses optimization of finishing honing process for surface quality and production rate

The finishing honing process is an effective machining to enhance surface properties. The objective of this work is to optimize the machining parameters, including the tangential speed (H), linear speed (L), and grit size (G) for minimizing the average roughness (Ra), maximum height roughness (Ry), and machining time (TM). The honing experiments were performed with the aids of an industrial machine and the Box–Behnken experimental matrix. The nonlinear relationships between machining parameters and honing responses were developed using response surface method models. Subsequently, two optimization techniques, including the desirability approach and non-dominated sorting genetic algorithm II (NSGA II), were used to solve the trade-off analysis among three technological responses and find the optimal factors. Finally, the machining time reductions were assessed in consideration of constrained roughness properties. The obtained results showed that surface roughness and machining time were strongly influenced by abrasive grit size, followed by the tangential speed and linear speed. The optimal values of the H, L, and G were 36.0 m/min, 9.5 m/min, and 220 FEPA, respectively. The reductions in the average roughness, maximum height roughness, and machining time are 53.13%, 8.93%, and 13.95%, respectively, as compared to common values used. Moreover, the genetic algorithm-based approach could be employed to produce reliable values in comparison with the desirability approach. The outcome is expected as a technical solution to enhance the surface properties and productivity of the finishing honing process. © 2020, The Brazilian Society of Mechanical Sciences and Engineering.