j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 8 1 e2 1 9 4

Available online at www.sciencedirect.com

journal homepage: www.elsevier.com/locate/jmrt

Original Article

Prediction of residual stresses in turning of pure

iron using artificial intelligence-based methods

Ahmed B. Khoshaim a, Ammar H. Elsheikh b,*, Essam B. Moustafa a,

Muhammad Basha a, Ahmed O. Mosleh c
a
Mechanical Engineering Department, Faculty of Engineering, King Abdulaziz University (KAU), P.O. Box 80204,
Jeddah, Saudi Arabia
b
Department of Production Engineering and Mechanical Design, Tanta University, 31527, Tanta, Egypt
c
Shoubra Faculty of Engineering, Benha University, Shoubra St. 108, Shoubra, P.O. 11629, Cairo, Egypt

article info abstract

Article history: Residual stresses (RS) induced in machined components have substantial impact on the
Received 11 January 2021 quality and lifetime of the final products. There are several cutting parameters and conditions
Accepted 9 February 2021 that affect the generation of RS, so understanding the relationship between the RS generation
Available online 17 February 2021 and those parameters to minimize the induced tensile RS is a crucial issue. This paper pre-
sents a study on the utilization of artificial intelligence-based methods to model the RS
Keywords: generation during dry turning of DT4E pure iron. The experiments were designed based on
Machining central composite design method. The effects of the cutting parameters such as cutting
Turning speed, feed and cutting depth on the generated RSes in both circumferential and radial di-
Pure iron rections are investigated. Two hybrid artificial neural network (ANN) models are used to
Artificial neural network predict the process responses after training them using the experimental results. The pre-
Particle swarm optimization diction accuracy of the two models are enhanced via integration with two different meta-
Flower pollination algorithm heuristic optimization algorithms, namely particle swarm optimization (PSO) and flower
pollination algorithm (FPA). These optimization algorithms are used as subroutine algo-
rithms to determine the optimal parameters of the ANN model. The predicted results by the
proposed models were compared with the experimental results as well as those obtained by
standalone ANN. The accuracy of all models was evaluated using different statistical mea-
sures. The ANN-FPA had the best prediction accuracy followed by ANN-PSO. The coefficient of
determination of ANN-FPA has high values of 0.996 and 0.997 for radial RS and circumferential
RS, while they were 0.971 and 0.992 for ANN-PSO and 0.649 and 0.815 for standalone ANN.
© 2021 The Authors. Published by Elsevier B.V. This is an open access article under the CC
BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).

aspects in assessing the functional behavior and the quality of

1. Introduction the machined components due to their direct influence on the
product performance in service. According to its attributes
Residual stresses (RSes) created in the surface and subsurface (compressive or tensile), these stresses can be either beneficial
layers of machined components are one of the most crucial

* Corresponding author.
E-mail address: ammar_elsheikh@f-eng.tanta.edu.eg (A.H. Elsheikh).
https://doi.org/10.1016/j.jmrt.2021.02.042
2238-7854/© 2021 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativeco
mmons.org/licenses/by-nc-nd/4.0/).
2182 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 8 1 e2 1 9 4
or detrimental to the performance of machined parts [1e3].
Machined components often exhibit tensile and/or compres-
sive RSes, which are induced by surface thermal gradients
[4,5] and/or by differential plastic deformation [6e8]. It is well-
known that tensile RSes in the surface and subsurface layers
are usually detrimental to creep life, fatigue life and stress
corrosion cracking resistance, while compressive RSes are
usually beneficial to the same properties [9e11]. RSes may be
created by inhomogeneous plastic deformation resulted from
thermal and mechanical loading during chip formation pro-
cess, the interaction between the tool nose and flank regions
and the freshly machined surface, and structural deformation
of the workpiece [12]. Among all surface integrity character-
istics, RSes have the greatest effect on fatigue life of the
machined components [13]. Many investigations have been
carried out to model the formation mechanism of RSes state
during different machining process. Theoretical in-
vestigations (including analytical modeling and numerical
modeling) as well as experimental investigations have been
reported literature. Finite element method (FEM), as a
numerical-based modeling technique, has been applied to
model the induced RSes during the cutting process, in spite of
its limitations such as high computational cost, simplification
assumptions and the limited material behavior models [14].
Response surface methodology (RSM) has been employed to
model the induced RS as a function of cutting variables during
ultrasonic assisted machining of 4340 hardened steel [15]. The
vibration amplitude was the most significant parameter that
affects RS generation followed by feed rate and cutting ve-
locity. However, the depth of cut had an insignificant effect on
RS generation. The optimized cutting parameters at which
compressive RS are induced were determined. The effects of
tool geometry on the RSes generation in orthogonal turning of
Inconel718 alloy have been modeled using a hybrid Eulerian-
Lagrangian model [16]. A semi-analytical model was estab-
lished to determine RSes in thin-walled parts based on shells
and plates theories [17]. Another analytical model was
developed to model of the RSes formation mechanism based
on multivariable decoupling technique [18]. RSes distribution
during turning process has been determined using linear
inversion method considering various cutting parameters by
[19]. Nevertheless, the formation mechanism of the RSes is too
complex and the developments in the theory of plasticity are
not adequate to enable accurate prediction of RSes; addition-
ally, most of material properties required to achieve theoret-
ical calculations are not accurately known [20]. Therefore, the
application of advanced artificial intelligence (ANN) based
techniques to model RS in turning operations is a critical
subject to overcome the limitations of conventional modeling
techniques. ANN has been shown promising application in
modeling different mechanical processes and systems with
excellent accuracy and high generalization capabilities
[21e25]. ANN could be trained using experimental data ob-
tained using different design of experiment approaches which
have been reported as powerful statistical tools [26e31]. Then,
it can be used as a virtual machine to obtain more results that
could be used in optimizing the process using advanced
metaheuristic optimization approaches [32e34].
Various ANN models were employed to model different
machining responses of different materials such as the
surface roughness of AISI 1040 steel [35], tool wear during
turning of 100Cr6 bearing steel [36], surface roughness of
hardened EN 24T steel [37], chipetool interface characteristics
during hard turning of C-60, 42CrMo4 and 17CrNiMo4 steel
alloys [38], surface roughness of hardened SS410 steel [39] and
cutting forces during turning of AISI 4140 [40]. However, few
attempts have been reported in literature regarding the
application of ANN techniques in prediction of RSes induced
in machined components during machining operations. Ma-
chine learning algorithms (radial basis function neural
network (RBFNN), back-propagation neural network (BPNN)
and support vector machine (SVM)) have been employed to
predict the RS induced in of ball screw raceway during
whirling milling process [41]. SVM showed a superior predic-
tion performance compared to the other two algorithms. In
another study, ANN was integrated with genetic algorithm to
minimize surface roughness and surface residual stress of
Inconel718 alloy during turning operation [42]. A hybrid ANN/
FEM model was developed to predict the RS profile of hard
machined 52100 bearing steel [43]. ANN was integrated with
particle swarm optimization algorithm to optimize the
generated RSes profile during machining 100Cr6 steel.
Measured experimental data were used to train the ANN and
then the predicted data were optimized using genetic algo-
rithm to obtain the optimal cutting parameters. In another
study, ANN was applied as direct and inverse prediction tool
to predict RS during turning of 52100 bearing steel [44]. How-
ever, the investigations on the application of ANN in modeling
turning operations are still in its cradle, but it showed many
potential. Besides, the integration between traditional ANN
models and the innovative metaheuristic optimization algo-
rithms to obtain the optimal ANN parameters that maximize
its prediction accuracy of ANN is considered as a new era in
the application of ANN in engineering [45e49].
Pure iron is used in many engineering applications such as
the manufacture of gaskets, magnets, welding rods, fuse wire,
lighting conductors and magnetic resonance imaging scan-
ners due to its enhanced properties such as magnetic
permeability and thermal conductivity [50]. From machining
point of view, pure iron is classified as difficult-to-cut material
with poor machinability due to its high plasticity and low
hardness [51]. The high plasticity of pure iron causes a high
surface tensile residual stress and severe tool wear after
machining process [52]. The prediction of induced residual
stresses after machining of pure iron is a critical subject that
should be investigated to enhance the lifetime of the products.
Nevertheless, very little work on machining of pure iron has
been reported in literature. As previously mentioned, analyt-
ical and numerical modeling techniques suffer from model
complexity, existence of many simplification assumptions,
limitations of plasticity theories and high computational cost.
Therefore, artificial intelligence-based modeling techniques
could be used as a good alternative for those conventional
modeling techniques.
In this study, hybrid artificial intelligence models are
developed to model the RSes generation in both of circum-
ferential and radial directions during turning of pure iron
disks reported by Luo and Sun [54]. The experiments were
designed according to central composite design to minimize
the number of performed experiments. Then, statistical tools
 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 8 1 e2 1 9 4
Table 1 e The elemental composition of pure iron (DT4E).
Element Ni Cr Cu
Weight (%) 0.035 0.02 0.034
are used to analyze the experimental results. The experi-
mental data are used to train and test an ANN model in
addition to two hybrids ANN models, in which the ANN is
optimized using PSO and FPA. The prediction accuracies of the
three proposed models are compared using different statisti-
cal measures.
2. Material and methods
The experiments were carried out on DT4E pure iron samples
[54]. The elemental composition and mechanical/thermo-
physical properties of the investigated material are tabulated
in Table 1 and Table 2, respectively. The samples were cut into
disks (100 mm diameter and 8.5 mm thickness). All samples
were subjected to an annealing process to relief internal
stresses prior to the turning operation. A positioning disk
(95 mm diameter and 29 mm thickness) was used to fix the
samples on the cuck of the lathe. The surface of the posi-
tioning disk was covered with foam to absorb the mechanical
vibrations and minimize the cyclic impact during turning
operation. The experiments were carried out on CKA6140 CNC
horizontal lathe with spindle power of 5.5 Kw in dry condition.
The positioning accuracy is 0.04 mm in Z direction and
0.03 mm in X direction. The repeatability of positioning ac-
curacy is 0.016 mm in Z direction and 0.012 mm in X direction.
Carbide turning inserts (DCGT11T302) coated by TiAlN was
used to cut the samples. The inserts have a rhombic shape
with 55
including angle. The corner radius, relief angle and
rake angle of the inserts were 0.2 mm, 7⁰ and 12⁰, respectively.
A fresh insert was used for each experiment to minimize the
effects of tool wear on the machined surface. The inserts were
fixed on a tool holder with a type of SDFCR2020K11. The
positioning of samples was performed using dial indictor.
The experiments were designed according to central
composite design to minimize the number of performed ex-
periments [[54]]. Three control factors with five levels, namely
cutting speed (80, 120, 160, 200 and 240 m/min), feed (0.04, 0.08,
0.12, 0.16 and 0.20 mm/rev) and cutting depth (0.05, 0.10, 0.15,
0.20 and 0.25 mm) were considered in this study, as tabulated
in Table 3. The designed experiments and the experimental
results extracted from [54] are tabulated in Table 4.
The RSes were measured using X-ray stress analyzer
(XSTRESS 3000). The main measuring units consist of an X-ray
tube powered by a high voltage generator (5e30 kV and
0e10 mA), Xstress 3000 goniometer with c-inclination and c-
Table 2 e The mechanical/thermophysical properties of pure iron (DT4E).
Yield Tensile Elongation
strength strength (%)
(MPa) (MPa) (GPa)
166 313.6 30e50
2183
Cr S Mn Si Al P Fe
0.02 0.02 0.029 0.028 0.0023 0.0072 Bal.
oscillation ranges between 45
to þ45
and 6
to þ6
,
respectively, and a dual position detector with angular reso-
lution of 0.029
/pixel. The symmetrical inclining technique
was used by applying different c values of 0⁰, ±24.1⁰, ±35.3⁰,
and ±45.0⁰. The X-ray tube voltage and current were set at
20 kV and 2 mA, respectively. The applied diffraction plane
was (2 1 1) and diffraction angle was 156.4⁰ with an exposure
time of 8 s. Besides, the Poisson’s ratio and Young’s modulus
were set as 0.28 and 207 GPa, respectively. Surface residual
stress was calculated using sin 2 c method by XTronic soft-
ware. The measurements were performed at three positions
on the cleaned machined surface of the samples. The final
value of RSes was calculated as the mean of the three
measured values. Both radial and circumferential RSes were
measured and tabulated in Table 4.
3. Hybrid artificial intelligence models
3.1. Artificial neural networks (ANNs)
ANNs are artificial intelligence modeling techniques that
mimic the behavior of the human brain. They can learn by
examples and find out the nonlinear relationship between the
inputs and responses of a certain engineering system. They
have shown promising prediction capabilities in modeling
different engineering systems. One of the common used ANN
techniques is the multilayer perceptron (MLP) which is
considered as a feed-forward ANNs. In a typical MLP, there are
three main layers: input layer, hidden layer and an output
layer, as shown in Fig. 1a. The input layer acts as a data
receiver to the input data as it consists of a number of the
processing units (neurons) equals to the number of the inputs.
Then, the data is transferred to the hidden layers at which the
data is processed via passing through connected neurons. The
neuron acts as a summation unit to sum the inputs weights as
well as a predefined bias as shown in Fig. 1b. The total sum-
mation is passed through an activation function. Finally, the
processed data are transferred to the output layer neurons.
The training process of the MLP could be expressed in a
mathematical form considering M neurons in the input layer.
The input xi is received by k1 -th neuron, the neuron output
O1;k1 is calculated using Eq. (1) [55]:
X
M
O1;k1 ¼ wmk1 xm ; k1 ¼ 1; :::; K1 (1)
m¼0
Hardness Density Thermal Thermal
(HB) (kg/m3) conductivity expansion
(W/m.K) coefficient (1/K)
50e80 7820 41.8e62.8 10.2e6-12.2e6
2184 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 8 1 e2 1 9 4

3.2. Particle swarm optimization

Table 3 e The levels of the used control factors.
Control factor Level Particle swarm optimization (PSO) is a metaheuristic optimi-
2 1 0 þ1 þ2 zation technique proposed in [56]. The PSO mimics the birds
Cutting speed (m/min) 80 120 160 200 240 behavior during seeking the food sources. During the imple-
Cutting depth (mm) 0.05 0.10 0.15 0.20 0.25 mentation of the PSO, there are many particles, each of them
Feed (mm/rev) 0.04 0.08 0.12 0.16 0.20 has zi position which represents a solution of the problem.
Each particle has independent memory to store his best po-
sitions as well as the universal best position. The position of
The output of the input layer is used as an input to the the particle is updated to a new position zi ðt þ1Þ based on the
hidden layer, and the hidden layer output could be calculated information stored in the particle memory and its own ve-
using Eq. (2): locity vi .
! The population of the PSO is generated randomly using Eq.
X
Kh1
Oh;kh ¼ f wkh1; kh Oh1;kh1 ; kh ¼ 2; …; Kh ; h ¼ 1; …; Nh (4):
Kh1 ¼0

(2) Z ¼ BL þ rand * ðBU  BL Þ (4)

where fð:Þ denotes the activation function, w0;kh denotes the where BU and BL denote the search domain upper and lower
applied biases in the input layer, kh ¼ 1; …; Kh denotes the boundaries, respectively. Each particle zi of Z can update its
applied biases in the hidden layers, andwkm; kh wm,k1denotes velocity vi using Eq. (5):
the synaptic weights connecting the input and hidden neu-  p   g 
vi ðt þ 1Þ ¼ wvi ðtÞ þ c1 r1 zi ðtÞ  zi ðtÞ þ c2 r2 zi ðtÞ  zi ðtÞ
rons. Nh M and Kh Khdenote the number of the hidden layers
(5)
and the number of neurons of each layer, respectively.
The final output of the neuron is computed as summing all where r1 and r2 are numbers selected randomly, wdenotes the
weighted outputs of the hidden layer and could be computed inertia weight applied to accelerate the convergence, mean-
using Eq. (3): while c1 and c2 are the acceleration coefficients and tdenotes
the iteration number.
X
KN
Then, the new particle position is calculated using Eq. (6):
yl ¼ wkN; l ON;kN ; l ¼ 1; …; L (3)
kN ¼0
xi ¼ xi þ vi (6)
where L L denotes the total number of the output layer neu-
After that the PSO algorithm computes the fitness function
rons andwkN,l wkh ;l lare the synaptic weights connecting the g
of each particle. Then, the universal best solution zi and the
hidden and output neurons.
p
best particle positionzi are determined. These procedures are
implemented until a predefined stopping criterion is fulfilled.
The procedures of the PSO algorithm are presented in Algo-
rithm 1.

Table 4 e The designed experiments and the measured responses [[53]].

Exp. No. Cutting speed (m/min) Cutting depth (mm) Feed (mm/rev) Results
Radial RS (MPa) Circumferential RS (MPa)
1 160 0.15 0.12 132.9 341.9
2 120 0.2 0.16 135.7 355.4
3 80 0.15 0.12 102.3 315
4 160 0.15 0.12 135.3 338.2
5 120 0.1 0.08 86.8 286.3
6 160 0.05 0.12 143.8 356.4
7 160 0.15 0.12 132.3 341.8
8 200 0.2 0.08 111 331.8
9 160 0.25 0.12 124.2 331.5
10 160 0.15 0.12 144.3 342.9
11 160 0.15 0.12 125 353
12 160 0.15 0.2 197 404.6
13 160 0.15 0.04 78.7 261.4
14 120 0.1 0.16 143.5 360.2
15 160 0.15 0.12 137.1 339
16 240 0.15 0.12 169.8 366
17 200 0.1 0.08 102.6 327.1
18 200 0.2 0.16 191.5 374.3
19 120 0.2 0.08 88 297.4
20 200 0.1 0.16 196.8 382
 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 8 1 e2 1 9 4 2185

Fig. 1 e a) ANN structure; b) ANN neuron.

Algorithm 1. PSO procedures. 3.3. Flower pollination algorithm (FPA)

1 Initialization of the model parameters such as dimen-
sion d, number of particles Nand the search domain
upper and lower boundaries (BU and BL ).
2 Generation of random solutionsZ.
3 Generation of the solutions velocities vi .
4 While stopping criterion is not fulfilled.
5 For all model particles.
6 Compute the value of the fitness function.
p
7 Update the best position of the particlezi .
8 Update the best universal position zg .
9 Update the particle velocity using Eq. (5).
10 Update the particle position using Eq. (6).
11 End for.
12 End while the universal best solution is obtained.
FPA is an evolutionary metaheuristic optimization technique
that emulates the flowers pollination process [57]. The natural
pollination process of flowers is accomplished via transferring
pollen by pollinators such as insects, bats and birds. Some
kinds of flowers have special pollinator partnership with some
kinds of pollinators. In other words, some flowers can be
pollinated by a certain kind of insects.
Natural pollination has two main kinds biotic and abiotic.
Biotic pollination occurs via transferring pollen by pollinators
and it may be found in more than 90% of flowers. On the other
hand, abiotic pollination occurs via diffusion caused by wind
without any pollinators and it may be found in less than 10%
of flowers. In FPA, pollinators are called pollen vectors and
they have numerous kinds. There is also a very important
phenomenon that occurs in some kind of pollinator called
2186 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 8 1 e2 1 9 4

Fig. 2 e Flow chart of the ANN-PSO and ANN-FPA for prediction of RS.

flower constancy which means that pollinators visit some
flower species and bypass other species. This phenomenon
helps in increasing the reproduction of certain kinds of flower
species via maximizing the pollen transferred to them. It also
helps in enhancing the performance of exploring and learning
process of pollinators.
There are two main kinds of pollination: cross-pollination
and self-pollination. The biotic cross-pollination is
considered as global pollination as it occurs via transferring
the pollens for long distance by pollinators. Pollinators of this
kind of pollination may also follow Levy distribution during
flying or jumping.
The pollination process can be summarized in the
following rules [57]:
 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 8 1 e2 1 9 4 2187

Fig. 3 e Effect of cutting factors means on: a) radial RS; b) circumferential RS.

1. Global pollination occurs via biotic cross-pollination which 4. Both of global and local pollination follow a switch
follows Levy distribution. probability.
2. Local pollination occurs via abiotic self-pollination.
3. Flower constancy is the phenomenon that represents the The global biotic optimization could be defined using Eq.
reproduction probability of two flowers. (7):
2188 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 8 1 e2 1 9 4

9 Else.
  10 Select ε randomly from a uniform distribution.
ytþ1
i ¼ yti þ LD yti þ F (7)
11 Select randomly the pollens of two different
whereydenotes the position for pollen iat iteration t, Fdenotes flowers (jand k).
the most fittest solution and LD denotes the pollination 12 The local pollination is computed based on Eq. (9).
strength defined from the levy distribution and could be 13 End if.
expressed using Eq. (8): 14 Update the population using the new solutions.
15 End For.
mGðmÞsinðpm=2Þ
LD  (8) 16 Find the universal best solution F.
ps1þq
17 End while.
where GðmÞdenotes the gamma function, sdenotes the long
distance step and q denotes the step constant.
The local biotic optimization could be defined using Eq. (9): 3.4. Implementation of hybrid models
 
ytþ1
i ¼ yti þ ε ytj  ytk (9)
The training of ANN could be considered as a minimization
where jand kdenote the pollens of two different flowers and problem in which the biases and the weights of the ANN
εis a randomly selected parameter from a uniform distribution should be determined to minimize the error between the
such that 0  ε  1. The procedures of the FPA algorithm are predicted values and the actual ones. Back-propagation such
presented in Algorithm 2. as LevenbergeMarquardt algorithm is the commonly used
algorithm during the training process. However, the applica-
Algorithm 2. : The FPA procedures tion of this algorithm in the training process consumes long
time and there is high tendency to trap into local minima.
1 Setting the objective function and the optimization Therefore, the integration between ANN and the advanced
factors. metaheuristic optimization techniques is highly desirable to
2 Initialization of the population with n flowers with avert the drawback of the conventional training algorithms
random solutions. and consequently improve the prediction accuracy of the
3 Compute the fittest solutionF. ANN.
4 Define the reproduction probability. Both ANN-PSO and ANN-FPA are proposed here as hybrid
5 While stopping criterion is not fulfilled. ANN models in which PSO and FPA are utilized as optimiza-
6 For all model flowers. tion techniques to minimize the prediction errors of the ANN
7 If the random solution is less than the reproduction by determining the optimum values for the weights and bia-
probability. ses of the network. The objective function can be defined
8 The global pollination is computed based Eq. (7). using Eq. (10):

Fig. 4 e Contour plots of radial RS as a function of: a) cutting depth and feed, b) cutting depth and cutting speed, c) feed and
cutting speed; circumferential RS as a function of: d) cutting depth and feed, e) cutting depth and cutting speed, f) feed and
cutting speed.
 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 8 1 e2 1 9 4
Fig. 5 e a) The predicted radial RS using the three proposed algorithms; b) The absolute error between the predicted radial RS
obtained by the three developed algorithms and experimental data; c) The predicted circumferential RS using the three
proposed algorithms; d) The absolute error between the predicted circumferential RS obtained by the three developed
algorithms and experimental data.
vffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
u X
u1 S X H
 2
OBðwi ; bi Þ ¼ t Tij  Pij ðwi ; bi Þ
s i¼1 j¼1
where OBdenotes the objective function, Tij denotes the target
value and Pij denotes the predicted data using wi and bi as
weight and bias, respectively. Sand Hare the number of
training samples and hidden neurons, respectively. The PSO
or FPA updates the ANN until reaching the stop criterion. The
flow chart of the ANN-PSO and ANN-FPA for prediction of RS is
presented in Fig. 2.
3.5. Model assessment measures
To assess the prediction accuracy of the three investigated
artificial intelligence models (ANN, ANN-PSO and ANN-FPA) to
predict circumferential RS and radial RS during turning of
pure iron, six statistical measures are computed, namely
determination coefficient (R2), mean absolute error (MAE), root
mean square error (RMSE), variation coefficient (COV),
efficiency coefficient (EC), and overall index (OI) [55].
4. Results and discussions
4.1. Effects of control variables on the residual stresses
generation
In this section, the effects of the investigated process factors
(cutting speed, cutting depth and feed) on the induced RSes of
the machine surfaces are investigated. The measured data of
radial and circumferential RS for all tested samples are tabu-
lated in Table 4. The circumferential RS is much higher than
radial RS for all investigated samples. Figure 3 shows the main
effect plots of the investigated cutting factors on the induced
RS. The plotted data reveal that the feed has a dominant effect
2189
on the induced RS in both of radial and circumferential di-
rections. Additionally, cutting speed has a moderate effect on
(10) the induced RS in both directions, while cutting depth has
insignificant effect on them. Increasing the feed and cutting
speed causes a significant increase and a moderate increase in
the induced RS, respectively; whereas, the RS slightly de-
creases by applying large cutting depth. From Fig. 5, it is
detected that the effects of all investigated cutting factors on
the induced RS in both of radial and circumferential directions
have the same trends. Therefore, the total induced RS is
significantly affected by increasing the feed and cutting speed,
while it is slightly affected by cutting depth.
The contour plots of radial and circumferential RS as a
function of different process factors are shown in Fig. 4. To
minimize the circumferential and radial RS, while preserving
the material removal rate as high as possible, it is recom-
mended to use high cutting depth, moderate cutting speed
and low feed as shown in Fig. 4. The use of high cutting speed
minimize the heat absorbed by the machined samples as the
largest portion of heat is evacuated via the chip; consequently
the thermal effects which are responsible for the tensile RS
generation is decreased. On the other hand, increasing the
cutting speed more than 180 m/min results in decreasing the
plastic deformation of the machined surface; consequently
the tensile effects are dominant and the RS increases.
Increasing the feed increases the material removal rate and,
consequently, the cutting forces also increase. The high cut-
ting forces generate excessive heat and consequently the
thermal effects are dominant, which cause a considerable
increase in surface tensile RS. Among all process factors,
cutting depth has a trivial effect on the induced RS which may
be neglected compared with the effect of cutting speed and
feed. Therefore, it is recommended to apply high cutting
depth to obtain maximum material removal rate with mini-
mal induced RS to compensate the reduction of feed and
cutting speed.
2190 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 8 1 e2 1 9 4
Fig. 6 e Comparison of experimental data and predicted radial and circumferential RS obtained by the three proposed
models.
4.2. Models validation
The measured RS data in both circumferential and radial di-
rections are used to train the proposed artificial intelligence
models, namely ANN, ANN-PSO and ANN-FPA, which are
utilized as prediction tools to determine the induced RS under
the investigated cutting parameters. These models are used to
learn the relationship between process control factors (cutting
speed, feed and cutting depth) and process control responses
(circumferential RS and radial RS). The experimental data are
allocated into two datasets; the first is the training dataset,
which represents 70% of the experimental data, while the
second is the test dataset, which represents 30% of the
experimental data. This division is applied for the two
measured RS (circumferential RS and radial RS). After the
training of the models and obtaining the optimal model con-
figurations and parameters that maximize the model accu-
racy, the models are tested and evaluated using different
statistical measures. The ANN-FPA accuracy is compared with
the other two models, namely ANN and ANN-PSO, for pre-
dicting the induced RS under various combinations of cutting
parameters.
Figure 5a displays the measured and predicted the radial
RS using the three proposed models. The best agreement is
observed between the measured data and ANN-FPA predicted
data followed by ANN-PSO predicted data, while ANN pre-
dicted data showed the worst agreement with measured ones.
The absolute error between the predicted radial RS data using
the three proposed models and the actual measured ones is
plotted in Fig. 5b. The predicted results using ANN have the
highest absolute error among all investigated models. The
maximum ANN absolute error reaches a high value of
67.65 MPa, while the maximum absolute error for ANN-PSO
and ANN-FPA was 23.11 MPa and 5.01 MPa, respectively. The
same trend could be observed in case of circumferential RS as
shown in Fig. 5c. The best agreement is observed between the
measured data and ANN-FPA predicted data followed by ANN-
PSO predicted data, while ANN predicted data showed the
worst agreement with measured ones. The predicted results
using ANN-FPA have the lowest absolute error among all
investigated models. The maximum ANN absolute error rea-
ches a high value of 38.31 MPa, while the maximum absolute
error for ANN-PSO and ANN-FPA was 8.62 MPa and 4.73 MPa,
respectively. Moreover, in some cases, the predicted results
using ANN-FPA have extremely low absolute error, which
approaches zero. Therefore, the results plotted in Fig. 5 proved
the outperformance of the ANN-FPA model over ANN and
ANN-PSO in predicting the process responses (circumferential
RS and radial RS).
Figure 6 presents a comparison between the measured
data and the predicted data by the three established models
 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 8 1 e2 1 9 4 2191

Table 5 e Evaluation of the three proposed algorithms using different statistical measures.
R2 RMSE MAE COV EC OI
Radial RS ANN 0.64999 22.70861 17.942 18.42955 0.549823 0.678932
ANN-PSO 0.97102 6.582459 3.290623 4.988055 0.962175 0.953266
ANN-FPA 0.996893 2.085536 1.222107 1.546918 0.996203 0.989287
Circumferential RS ANN 0.81576 15.56632 10.94026 4.602145 0.765858 0.828577
ANN-PSO 0.99267 2.794531 1.33366 0.82004 0.992454 0.986469
ANN-FPA 0.997528 1.815983 0.926801 0.534973 0.996813 0.992066

for the circumferential RS and radial RS. The results of the
predicted data by each model for both RS directions are
plotted as subfigures in Fig. 6. For the subfigures of ANN-FPA,
predicted points are scattered very closely around the straight
line, which indicates the high accuracy of the ANN-FPA
model. On the other hand, predicted points of ANN are scat-
tered randomly away from the straight line, which indicates
the low accuracy of the ANN model. The high accuracy of the
ANN-FPA model over the ANN and ANN-PSO models is
attributed to the vital role of the FPA to determine the optimal
ANN parameters. For ANN-FPA results, R2 has high values of
0.99 for both of circumferential RS and radial RS. This R2 is a
little bit higher than that of ANN-PSO, which has 0.97 and 0.99
for radial RS and circumferential RS, respectively. Both of
ANN-FPA and ANN-PSO have much higher R2 compared with
ANN, which shows 0.64 and 0.81 for radial RS and circumfer-
ential RS, respectively.
Comparisons between the three proposed models using
different statistical measures (R2, RMSE, MAE, COV, EC and OI)
for both of circumferential RS and radial RS are presented in
Table 5. The results presented in that table indicated that
ANN-FPA has the highest values of R2, EC and OI followed by
ANN-PSO and ANN. Besides, ANN-FPA has the lowest RMSE,
COV and MAE values compared with ANN-PSO and ANN
models. The increase in R2, EC and OI values, as well as the
decrease in RMSE, COV and MAE values, points out the out-
performance of ANN-FPA over ANN-PSO and ANN models.
The RMSE of the ANN-FPA model for the radial RS is rep-
resents only 9.18% and 31.68% of that of ANN and ANN -PSO,
respectively, whereas it represents 11.66% and 64.98% of that
of ANN and ANN-PSO, respectively, in case of circumferential
RS. The MAE of the ANN-FPA model for the radial RS repre-
sents only 6.81% and 37.13% of that of ANN and ANN -PSO,
respectively, whereas it represents 8.47% and 69.49% of that of
ANN and ANN-PSO, respectively, in case of circumferential
RS. The lower RSME and MAE values indicate the high pre-
diction accuracy of the model ANN-FPA compared with other
models.
The COV of the ANN-FPA model for the radial RS is lower
than 6.81% and 37.13% of that of ANN and ANN-PSO, respec-
tively, whereas it is lower than 8.47% and 69.49% of that of
ANN and ANN-PSO, respectively, in case of circumferential
RS. The low value of the COV of the ANN-FPA revealed the
high accuracy of the model compared to the others. The
values of EC and OI are very close to unity in case of ANN -PSO
and ANN-FPA and they are very far from the unity in case of
ANN. This is another indicator of the outperformance of ANN
-PSO and ANN-FPA over ANN. The results tabulated in Table 5
are graphically presented in in the spider charts shown in
Fig. 7, which clearly reveal the variance between the six sta-
tistical measures (R2, MAE, COV, RMSE, EC and OI) for the three
established models and for radial RS and circumferential RS.
The high values of R2, OI and EC and low values of RSME, VC
and MAE reveal a better accuracy of the model, and thus better
fit between predicted and experimental results is obtained.
Overall, based on the results plotted in Figs. 5e7 and
tabulated in Table 5, it can be concluded that the ANN-FPA
and ANN-PSO models are more accurate than ANN model
and they can be utilized to predict circumferential RS and
radial RS during turning of pure iron with high accuracy.

Fig. 7 e Spider plot of the statistical measures of the three proposed models for: a) radial RS, b) circumferential RS.
2192 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 8 1 e2 1 9 4
5. Conclusion
In this study, hybrid artificial intelligence models were applied
to model the RSes generation in turning of DT4E pure iron. The
effects of different cutting parameters, such as cutting speed,
feed and cutting depth, were investigated and analyzed using
statistical tools. The feed has a dominant effect on the
induced RS followed by cutting speed, while cutting depth has
insignificant effect on the induced RS. Increasing the feed and
cutting speed causes a significant increase and a moderate
increase in the induced RS, respectively; whereas, the RS
slightly decreases by applying large cutting depth. Therefore,
to minimize the induced RSes, while preserving the material
removal rate as high as possible, it is recommended to use
high cutting depth, moderate cutting speed and low feed. Two
hybrid artificial intelligence models were developed to predict
the induced RSes based on different cutting parameters.
These models consist of a conventional artificial neural
network model incorporated with particle swarm optimiza-
tion and flower pollination algorithm. The developed hybrid
models had better prediction accuracy compared with that of
the standalone model. This is due to the role of optimization
algorithms in obtaining the model parameters that maximize
the prediction accuracy.
Declaration of Competing Interest
The authors declared that there is no conflict of interest.
Acknowledgement
This research work was funded by institutional fund project
under grant no (IFPHI-301-135-2020). Therefore, authors
gratefully acknowledge technical and financial support from
the ministry of education and king Abdulaziz university, DSR,
Jeddah, Saudi Arabia.
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