AI Optimization of Casting Sandpaper for Enhanced Surface Finish and Process Efficiency

Authors

  • Hamza A. Ghulman University of Science and Technology (UBT), Jeddah, Saudi Arabia

DOI:

https://doi.org/10.31181/rme508

Keywords:

Artificial intelligence (AI), Efficiency, Artificial Neural Networks, Genetic Algorithms, Casting Process

Abstract

This study explores the integration of artificial intelligence (AI) techniques into the casting surface finishing process using abrasive sandpaper. The aim is to optimize surface roughness, enhance efficiency, and extend abrasive life while maintaining cost-effectiveness. Machine learning models including Random Forest, Support Vector Regression, and Artificial Neural Networks are developed based on experimental data. The study also applies Genetic Algorithms and Particle Swarm Optimization for multi-objective process optimization. Results show significant improvements in prediction accuracy and process control, presenting a data-driven framework for smarter manufacturing.

References

Abu-Mahfouz, I., El Ariss, O., Esfakur Rahman, A., & Banerjee, A. (2017). Surface roughness prediction as a classification problem using support vector machine. The International Journal of Advanced Manufacturing Technology, 92(1), 803-815. https://doi.org/10.1007/s00170-017-0165-9

Bhoskar, M. T., Kulkarni, M. O. K., Kulkarni, M. N. K., Patekar, M. S. L., Kakandikar, G., & Nandedkar, V. (2015). Genetic algorithm and its applications to mechanical engineering: A review. Materials Today: Proceedings, 2(4-5), 2624-2630. https://doi.org/10.1016/j.matpr.2015.07.219

Brinksmeier, E., TÖnshoff, H. K., Czenkusch, C., & Heinzel, C. (1998). Modelling and optimization of grinding processes. Journal of Intelligent Manufacturing, 9(4), 303-314. https://doi.org/10.1023/A:1008908724050

Davim, J. P. (2015). Modern manufacturing engineering. Springer. https://doi.org/10.1007/978-3-319-20152-8

Gaspar-Cunha, A., & Covas, J. A. (2008). Robustness in multi-objective optimization using evolutionary algorithms. Computational optimization and applications, 39(1), 75-96. https://doi.org/10.1007/s10589-007-9053-9

Hastie, T., Tibshirani, R., Friedman, J., & Franklin, J. (2005). The elements of statistical learning: data mining, inference and prediction. The Mathematical Intelligencer, 27(2), 83-85. https://link.springer.com/book/10.1007/978-0-387-84858-7

Jain, N., Nangia, U., & Jain, J. (2018). A review of particle swarm optimization. Journal of The Institution of Engineers (India): Series B, 99(4), 407-411. https://doi.org/10.1007/s40031-018-0323-y

Janardhan, M. (2015). An integrated evaluation approach for modelling and optimization of surface grinding process parameters. Materials Today: Proceedings, 2(4-5), 1622-1633. https://doi.org/10.1016/j.matpr.2015.07.089

Kadirgama, K., Noor, M., & Rahman, M. (2012). Optimization of surface roughness in end milling using potential support vector machine. Arabian Journal for Science and Engineering, 37(8), 2269-2275. https://doi.org/10.1007/s13369-012-0314-2

Kalpakjian, S., & Schmid, S. R. ( 2014). Manufacturing Engineering and Technology. 7th ed., Boston, MA, USA: Pearson. https://www.scirp.org/reference/referencespapers?referenceid=2901051

Kalyanmoy, D. (2001). Multi-objective Optimization using Evolutionary Algorithms. Hoboken, NJ, USA: Wiley. https://www.wiley.com/en-us/Multi-Objective+Optimization+using+Evolutionary+Algorithms-p-9780471873396

Kennedy, J., & Eberhart, R. (1995). Particle swarm optimization. In Proceedings of ICNN'95-international conference on neural networks (Vol. 4, pp. 1942-1948). ieee. https://doi.org/10.1109/ICNN.1995.488968

Kumar, M., Husain, D. M., Upreti, N., & Gupta, D. (2010). Genetic algorithm: Review and application. Available at SSRN 3529843. https://doi.org/10.2139/ssrn.3529843

Lee, C. K. H. (2018). A review of applications of genetic algorithms in operations management. Engineering Applications of Artificial Intelligence, 76, 1-12. https://doi.org/10.1016/j.engappai.2018.08.011

Mamalis, A. (2005). Advanced manufacturing engineering. Journal of materials processing technology, 161(1-2), 1-9. https://doi.org/10.1016/j.jmatprotec.2004.07.055

Patwari, A. U., Bhuiyan, S. A., Noman, K., & Ul Navid, W. (2024). Defects and remedies in casting processes: a combinatorial approach between manual and digital optimization technique for enhanced quality casting. Discover Mechanical Engineering, 3(1), 39. https://doi.org/10.1007/s44245-024-00067-2

Ruppert, D. (2004). The elements of statistical learning: data mining, inference, and prediction. In: Taylor & Francis. https://doi.org/10.1198/jasa.2004.s339.

Wang, D., Tan, D., & Liu, L. (2018). Particle swarm optimization algorithm: an overview. Soft computing, 22(2), 387-408. https://doi.org/10.1007/s00500-016-2474-6

Yeganefar, A., Niknam, S. A., & Asadi, R. (2019). The use of support vector machine, neural network, and regression analysis to predict and optimize surface roughness and cutting forces in milling. The International Journal of Advanced Manufacturing Technology, 105(1), 951-965. https://doi.org/10.1007/s00170-019-04227-7

Zitzler, E., & Thiele, L. (1998). Multiobjective optimization using evolutionary algorithms—a comparative case study. In International conference on parallel problem solving from nature (pp. 292-301). Springer. https://doi.org/10.1007/bfb0056872

Downloads

Published

2025-12-16

How to Cite

AI Optimization of Casting Sandpaper for Enhanced Surface Finish and Process Efficiency. (2025). Reports in Mechanical Engineering, 6(2), 16-22. https://doi.org/10.31181/rme508