Machinability analysis in wire-EDM of cryogenically treated Ti6Al4V alloy and multi-objective optimization using MOAVOA and MOGA

Machinability analysis in wire-EDM of cryogenically treated Ti6Al4V alloy and multi-objective optimization using MOAVOA and MOGA

[ad_1]

Single objective optimization using GA and AVOA

This section presents a single objective optimization of MRR_CT and Ra_CT using GA and AVOA algorithms. GA is a well-known optimization technique inspired by the principles of natural selection and genetics. It simulates the process of evolution to find optimal or near-optimal solutions to complex real-life problems and works with a population of potential solutions, evolving them over generations through operations such as selection, crossover, and mutation. By iteratively improving the solutions based on a fitness function, GA effectively explores the search space to discover high-quality solutions55. On the other hand, the African vultures optimization algorithm (AVOA) is a metaheuristic inspired by the scavenging behavior of African vultures. It emulates how vultures search for food using visual and sensory cues, striking a balance between exploring new areas and refining known good solutions. The algorithm starts with a population of potential solutions (vultures), evaluates their effectiveness, and adjusts their positions to enhance the quality of solutions44. The convergence plot in Fig. 12 shows that AVOA converges faster than GA and outperforms it in finding minimum Ra_CT and maximum MRR_CT values. The minimum Ra_CT values obtained using GA and AVOA are 4.85 and 4.81 respectively while for MRR_CT the values are 6.77 and 6.84 respectively.

Fig. 12
figure 12

Convergence plot for RA_CT and MRR_CT using GA and AVOA respectively.

MOGA (multi objective genetic algorithm)

In 1993, a groundbreaking advancement emerged in genetic algorithms with the introduction of the multi objective genetic algorithm (MOGA)56. This innovative approach prioritized identifying and preserving non-dominated solutions within a GA population, enhancing both solution optimality and diversity. Unlike traditional GA, MOGA redefined the fitness assignment process, focusing explicitly on non-dominated solutions while fostering a diverse array of solutions. MOGA stands out as a potent direct search technique tailored for tackling complex multi-objective optimization problems. Leveraging genetic algorithm principles, MOGA’s utilize their population-centric nature to explore multiple Pareto-optimal solutions simultaneously, contrasting with methods fixed on singular Pareto optimality. Successfully navigating multi-objective optimization via genetic algorithms requires a nuanced balance of elitism and solution diversity throughout the evolutionary process.

Procedure of MOGA

A straightforward method for combining several goal variables into an integer performance function is the weighted sum technique.

$$f\left( x \right) = w_ troy electrical company \cdot f_ troy electrical company \left( x \right) + \cdots + w_{n} f_{n} \left( x \right),$$

(4)

Here, n is the number of objective functions, x is an integer (i.e., an individual), f(x) is the sum of the performance function, and fi(x) is the i-th objective function. Wi is a constant weight for fi(x). The search direction in genetic algorithms becomes fixed if we use constant weights wi in Eq. (4). Therefore, using a variety of search strategies, we provide a selection process that includes random weights to investigate Pareto optimum solutions. When selecting a couple of strings for a crossover operation, we assign an arbitrary real number to each weight as follows:

$$W_{i} = \left( {\frac{random i\left( \cdot \right)}{{\mathop \sum \nolimits_{j = 1}^{n} random j\left( \cdot \right)}}} \right)\quad {\text{i}} = troy electrical company, electrical installation, residential electrician, generator installation \ldots ,{\text{n}}.$$

(5)

A positive random integer is shown here by random j(·). Equation (5) indicates that wi assumes a real value inside the range [0, 1]. Step by step procedures of MOGA are as follows:

Step 1: Initialization

Generate an initial population comprising Npop strings, where Npop represents the number of strings in each population.

Step 2: Evaluation

Compute the objective function values for the generated strings. Update a preliminary set of Pareto optimal solutions.

Step 3: Selection

Determine the fitness value of each string using random weights. Selecting pairs of strings from the current population based on a selection probability.

Repeat this process to select Npop/2 pairs of strings from the current population.

Step 4: Crossover

For each selected pair, perform a crossover operation to create two new strings. Generate N pop new strings through the crossover operation. (It’s a genetic operation where two parent solutions are combined to create one or more offspring solutions. This is typically done by exchanging information between the parents to explore new areas of the search space.)

Step 5: Mutation

Apply a mutation operation with a specified mutation probability for each bit value of the strings generated by the crossover operation. (It’s a genetic operation where a small random change is applied to a single solution in order to introduce diversity and prevent premature convergence. Mutation helps explore new regions of the search space that might lead to better solutions).

Step 6: Elitist strategy

Randomly remove Nelite strings from the set of Npop strings generated in the previous steps. Replace them with Nelite strings randomly chosen from a preliminary set of Pareto optimal solutions.

Step 7: Termination test

If a predetermined stopping condition is not met, return to Step 1.

Step 8: User selection

Present the final set of Pareto optimal solutions to the decision maker. The best solution is then chosen according to the decision maker’s preference. The flowchart is shown in Fig. 13.

Fig. 13
figure 13

Multi objective African vulture optimization algorithm (MOAVOA)

The multi objective African vultures optimization algorithm (MOAVOA) was introduced by Khodadadi et al.50 for solving different real life non-trivial multi-objective problems. The MOAVOA involves integration of three different mechanisms such as archive, grid mechanism and leader selection mechanism. African vultures’ hunting and navigational habits served as the model for the innovative metaheuristic technique known as MOAVOA. It comprises exploration and exploitation phases, with the latter further divided into cooperative and competitive phases. MOAVOA determines its current phase primarily based on the hunger level F of the vulture, transitioning to exploration if hunger is below a threshold (F < r1), cooperative if above another threshold (F > r2), and otherwise enters the competition phase. MOAVOA appoints two vulture leaders to guide the rest of the vulture population. Unlike traditional methods, MOAVOA recognizes that there isn’t just one best solution, but rather a range of good solutions. Therefore, it designates two sets of Socially dominant vultures. The first batch includes all non-dominated solutions within the group. Each vulture’s first Socially dominant is selected from this set based on diversity and convergence metrics. The tournament selection process ensures that the optimal solutions are selected, with priority given to lower density values and convergence measures. If there are ties, the solution with the preferable diversity measure is selected. The second set comprises the best solutions for each objective function across the entire vulture population. This selection process aims to identify solutions that are closest to the Pareto Front, guiding the convergence of each iteration’s hyperplane towards it. Each vulture in this set is tasked with guiding new vultures towards the ideal point of the Pareto Front. The selection of the second Socially dominant for each vulture involves a random assignment from this set. The selection processes for both sets are detailed in the algorithms provided. MOAVOA employs a set of reference points to locate evenly distributed solutions and those in close proximity to the Pareto front.

Procedure of MOAVOA

In the iterative process of MOAVOA, several crucial steps are taken. Firstly, socially dominant are identified to facilitate the movement of solutions within the decision space. Secondly, to promote diversity and prevent premature convergence, mutation is applied to a portion of the vulture positions. Thirdly, environmental selection is conducted to choose the top vultures for the subsequent generation. Lastly, the external Arc (Archive) is updated to harbor only non-dominated solutions. These steps are conducted until the maximum iteration limit is reached.

In Eq. (6), the probability of selecting certain vultures to relocate others towards optimal solutions is calculated, with parameters \(L_ troy electrical company\) and \(L_ electrical installation\) ranging from 0 to 1 and the sum of both parameters 1.

$$R\left( i \right) = \left\{ {\begin{array}{*{20}l} {Best\;Vulture_ troy electrical company } \hfill & {\quad if\;p_{i} = L_ troy electrical company } \hfill \\ {Best\; Vulture_ electrical installation } \hfill & {\quad if\;p_{i} = L_ electrical installation } \hfill \\ \end{array} } \right.,$$

(6)

The chance that each group will select the optimal solution using the Roulette wheel technique is found using Eq. (7).

$$P_{i} = \frac{{F_{i} }}{{\mathop \sum \nolimits_{i = 1}^{n} F_{i} }},$$

(7)

Equation (8) simulates the shift in vulture behavior from the stages of exploration to exploitation, based on the pace at which vultures get satisfied or their appetite declines. This formula represents the declining trend in satiation and directs behavior in that direction. \(F\) indicates that the vultures are full. \(z\) ∈ (− 1, 1) is a random number. \(H\) ∈ (− 2, 2) is a random number, while \(rand_ troy electrical company\), \(rand_{p1}\) varies ∈ (0, 1). If \(z\) falls below 0, the vulture is considered starved, while reaching 0 indicates satiation.

$$t = h \times \left( {sin^{w} \left( {\frac{\pi } electrical installation \times \frac{{iteration_{i} }}{maxiterations}} \right) + cos\left( {\frac{\pi } electrical installation \times \frac{{iteration_{i} }}{maxiterations}} \right) – 1} \right),$$

(8)

$$F = \left( {2 \times rand_ troy electrical company + 1} \right) \times z \times \left( {1 – \frac{{iteration_{i} }}{maxiterations}} \right) + t,$$

(9)

Before the optimization process begins, the parameter w is first given a fixed value. It serves as a barometer for how much the optimization procedure influences the phases of discovery and development. As w increases in value, there is a greater chance of going into the exploration phase during the last phases of optimization. Conversely, when the parameter w is reduced, the probability of entering the exploration phase falls. The values given to the parameter w determine how the objective function, F, and the iteration number, t, behave during the optimization process.

To determine which strategy to employ during the exploration phase, randP1 ∈ (0, 1) is generated. If P1 ≥ randP1, Eq. (12) is utilized. However, if P1 < randP1 Eq. (13) is applied.

$$P\left( {i + 1} \right) = \left\{ {\begin{array}{*{20}l} {Equation\;\left( electrical contractor \right)} \hfill & {\quad if\;p_ troy electrical company \ge rand_{p1} } \hfill \\ {Equation\;\left( power system repair \right)} \hfill & {\quad if \;p_ troy electrical company < rand_{p1} } \hfill \\ \end{array} } \right.$$

(10)

$$P\left( {i + 1} \right) = R\left( i \right) – D\left( i \right) \times F,$$

(11)

$$D\left( i \right) = \left| {X \times R\left( i \right) – P\left( i \right)} \right|$$

(12)

In Eq. (11), vultures haphazardly search for food in the vicinity of the best civilizations of either of the two tribes. Here, F represents the rate of satiation, which was determined by applying Eq. (9) in the current iteration, and \(P\left( {i + 1} \right)\) represents the position coordinate of the vulture in the subsequent iteration. In this version, one of the best vultures chosen by Eq. (6) is shown in Eq. (12) as R(i). Moreover, X indicates the area where vultures sporadically relocate to protect food sources from other predators. X is a coefficient vector that increases random movement; it is different for every iteration and can be computed as X = 2 × rand, where rand ∈ (0, 1).

$$P\left( {i + 1} \right) = R\left( i \right) – F + rand_ electrical installation \times \left( {\left( {ub – lb} \right) \times rand_ residential electrician + lb} \right),$$

(13)

R(i) in Eq. (13) represents a single of the finest vultures chosen in the present iteration using Eq. (6). The vulture hunger rate, F, in this iteration is defined by Eq. (9) and rand2 ∈ (0, 1). The variables’ lower and upper bounds are represented by the variables lb and ub, respectively. When Eq. (13) is employed, the MOAVOA generates a basic model for randomly generating solutions in the range specified by lb and ub. The randomness coefficient is amplified by rand3, which affects the distribution of solutions. Random motion is added to lb by rand3, which favors solutions with comparable patterns as it gets closer to 1. This increases the degree of unpredictability in the search environment, encouraging variety and travel across different areas of the search field. Simple models are utilized in MOAVOA to represent vulture motion. At this stage, MOAVOA efficiency is examined. When |F|< 1, the MOAVOA transitions into the exploitation phase, comprising two sub-phases, each employing distinct strategies. The selection of strategies within each sub-phase is controlled by parameters P2 and P3, with P2 determining the strategies in the first sub-phase and P3 in the second. Both parameters ∈ (0, 1) and are set prior to the search operation. The vultures’ foraging behaviors are mathematically formulated for problem-solving purposes. The Initial sub phase of the exploitation phase is initiated by the MOAVOA when |F|∈ (0.5, 1). In this sub-phase, two distinct strategies are employed: siege-fighting and rotational flight. The selected and preset procedure is determined by P2 ∈ (0, 1). The first step in this sub-phase is to generate a random number, randP2 ∈ (0, 1). Gradually, the siege-fight strategy is applied if P2 ≥ randP2. On the other hand, the rotational flying method is used if P2 < randP2. Equation (14) provides specifics on this selection procedure.

$$P\left( {i + 1} \right) = \left\{ {\begin{array}{*{20}c} {Equation\;\left( electrical safety \right)} & {\quad if\;p_ electrical installation \ge rand_{p2} } \\ {Equation\;\left( lighting repair \right)} & {\quad if\;p_ electrical installation < rand_{p2} } \\ \end{array} } \right. ,$$

(14)

When the absolute value of |F|≥ 0.5, indicating that vultures are relatively satiated, competition for food intensifies. In such scenarios, where multiple vultures converge on a single food source, conflicts over food acquisition escalate. Physically dominant vultures typically prefer not to share food, exhibiting a reluctance to cooperate with others. On the other hand, less powerful vultures use a different approach, congregating nearer to more powerful ones in an effort to wear them out and steal food. Equations (15) and (16) are used to represent this behavior.

$$P\left( {i + 1} \right) = D\left( i \right) \times \left( {F + rand_ generator installation } \right) – d\left( t \right),$$

(15)

$$d\left( t \right) = R\left( i \right) – P\left( i \right)$$

(16)

D(i) is obtained by applying Eq. (12) to the vulture hunger rate F, which is provided by Eq. (9). The purpose of rand4 ∈ (0, 1) is to introduce unpredictability. The distance that exists between the vulture and a single of the most desirable vultures in each group is calculated using Eq. (16), where P(i) represents the vulture’s present vector position. In the current iteration, R(i) is selected using Eq. (6) as one of the best vultures from both groups.

Vultures’ rotational waving simulates spiral motion by using repeated spiraling motions. Spiral equations between all vultures and one of the top two vultures are used to numerically simulate this motion.

$$\begin{aligned} S_ troy electrical company & = R\left( i \right) \times \left( {\frac{{rand_ industrial electrician \times P\left( i \right)}}{2\pi }} \right) \times {\text{cos}}\left( {P\left( i \right)} \right) \\ S_ electrical installation & = R\left( i \right) \times \left( {\frac{{rand_ electrical maintenance \times P\left( i \right)}}{2\pi }} \right) \times \sin \left( {P\left( i \right)} \right) \\ \end{aligned}$$

(17)

$$P\left( {i + 1} \right) = R\left( i \right) – \left( {S_ troy electrical company + S_ electrical installation } \right),$$

(18)

Equations (17) and (18) describe circular flight, while Eq. (6) yields the displacement vector of a top vulture, represented by R(i). Furthermore, random numbers \(rand_ industrial electrician\) and \(rand_ electrical maintenance\) ∈ (0, 1) are used. Equation (17) is used to calculate S1 and S2, and Eq. (18) is used to update the locations of the vultures. Different vulture species congregate around the food supply during the second stage of exploitation, engaging in violent conflict and besieging each other in an effort to get food. When |F|< 0.5, this phase begins. randP3 ∈ (0, 1) at first. The tactic is to amass several kinds of vultures over the food supply if P3 ≥ randP3. On the other hand, aggressive tactics for siege and warfare are used if P3 < randP3. Equation (19) provides an explanation of this procedure.

$$P\left( {i + 1} \right) = \left\{ {\begin{array}{*{20}l} {Equation\;\left( {20} \right)} \hfill & {\quad if\;p_ residential electrician \ge rand_{p3} } \hfill \\ {Equation\;\left( {21} \right)} \hfill & {\quad if\;p_ residential electrician < rand_{p3} } \hfill \\ \end{array} } \right. ,$$

(19)

Vulture species congregating at a particular food source occurs when vultures are starving and face intense competition for food. This phenomenon is modeled using Eqs. (20) and (21).

$$A_ troy electrical company = BestVulture_ troy electrical company \left( i \right) – \frac{{BestVulture_ troy electrical company \left( i \right) \times P\left( i \right)}}{{BestVulture_ troy electrical company \left( i \right) – P\left( i \right)^ electrical installation }} \times F$$

(20)

$$A_ electrical installation = BestVulture_ electrical installation \left( i \right) – \frac{{BestVulture_ electrical installation \left( i \right) \times P\left( i \right)}}{{BestVulture_ electrical installation \left( i \right) – P\left( i \right)^ electrical installation }} \times F$$

(21)

\(BestVulture_ troy electrical company \left( i \right)\) in Eq. (21) represents the most effective vulture from the first set in the present iteration, and \(BestVulture_ electrical installation \left( i \right)\) represents the most effective vulture from the second group. F is the vulture hunger rate as calculated by Eq. (9), and P(i) is the vector position of a vulture at any given moment.

$$P\left( {i + 1} \right) = \frac{{A_ troy electrical company + A_ electrical installation }} electrical installation,$$

(22)

Equation (22), in which \(A_ troy electrical company\) and \(A_ electrical installation\) are obtained from Eqs. (20) and (21), is then used to calculate the aggregate of all vultures. The vulture’s position vector in the subsequent iteration is \(P\left( {i + 1} \right)\).

When there is intense rivalry for food, as shown when |F|< 0.5, dominant vultures lose energy and become weak, making it difficult for them to successfully compete with other vultures. Analysis is done on how every vulture moves in the direction of a food source. Occasionally, vultures are hungry. Because of their intense competition for food, many vulture breeds may congregate at just one food source. Equations (21) and (22) are used to explain this vulture behavior.

As |F|< 0.5, dominant vultures lose their ability to battle other vultures and become weak and famished. However, other vultures approach the dominant vulture from different directions, acting aggressively as they search for food. Equation (23) provides a description of this movement pattern.

$$P\left( {i + 1} \right) = R\left( i \right) – \left| {d\left( t \right)} \right| \times F \times Levy\left( d \right)$$

(23)

Equation (16) is used to calculate the distance, d
(24)

Equation (24) has d as the number of variables in the issue and u and v as arbitrary numbers. By default, the parameter β has a constant value of 1.5. The performance of Tallini et al.59 efficiency strategy is significantly impacted by the difficulty of computation, which is closely related to the maximum number of iterations (T), population size (N), and the dimensionality (D) of the problem. Below is a description of the computational analysis of the basic African vulture optimization algorithm (AVOA):

  1. (i)

    O(N) represents the computational difficulty of the starting phase.

  2. (ii)

    The computing cost of updating each vulture’s location is O (T − N − D).

  3. (iii)

    Finding the ideal location has an O (T − N) computational difficulty.

Consequently, the total computational difficulty of MOAVOA culminates in \(O\left( {N\left( {T – D + T + 1} \right)} \right)\). In the proposed MOAVOA, each vulture potentially updates its position utilizing either the random flight strategy (RFS) or the social attraction model (SAM) in every iteration, generating two candidate positions. The collective computational complexity of updating all vultures’ positions amounts to \(O\left( {2T – N – D} \right)\). Consequently, the overall computational complexity of MOAVOA stands at \(O\left( {N – \left( {2T – D + T + 1} \right)} \right)\).

Even if the processing load is significantly higher than with the original MOAVOA, it is worth noting that there is still a little chance of using RFS or SAM during the entire procedure. Given the improved optimization efficiency attained, the extra computational complexity that was incurred is considered to be reasonable. Figure 14 shows the working flowchart of MOVOA.

Fig. 14
figure 14

Optimization results and discussion of MRR_CT and Ra_CT

The performance of the multi objective African vulture optimization algorithm (MOAVOA) and multi objective genetic algorithm (MOGA) for the optimization of MRR_CT and Ra_CT based on input parameters including current (I), wire speed (WS), and duty cycle (DC) was evaluated. The algorithms were compared in terms of their ability to find pareto optimal solutions for the multi-objective optimization problem. The accurate setting of input parameters is crucial for obtaining reliable results, as emphasized by Wang et al.60. Therefore, extensive trials and rigorous procedures were undertaken prior to finalizing the parameters for the algorithms. The input parameters of MOAVOA and MOGA are depicted in Table 7.

Table 7 Parameters settings of MOAVOA and MOGA.

The results (Table 8) showed that MOAVOA and MOGA are capable of finding trade-off solutions between MRR_CT and Ra_CT. However, MOAVOA outperformed MOGA in terms of convergence speed and diversity of solutions. MOAVOA able to explore the search space more effectively, leading to a larger number of diverse Pareto-optimal solutions compared to MOGA. Furthermore, sensitivity analysis was conducted to investigate the influence of each input parameter on the optimization process. It was found that current had the most significant impact on both MRR_CT and Ra_CT, followed by wire speed and duty cycle. This information can be valuable for understanding the underlying dynamics of the optimization problem and for guiding parameter selection in practical applications.

Table 8 Optimized values of MRR_CT and Ra_CT of the two algorithms.

The results of this study demonstrate the effectiveness of MOAVOA and MOGA for the multi-objective optimization of MRR_CT and Ra_CT in WEDM processes. The optimality in results is demonstrated through pareto fronts generated by both algorithms and their closeness to optimal solutions confirming the adequate convergence and diversity of solutions61,62,63. However, MOAVOA exhibited superior performance in terms of solution quality and convergence speed. This can be attributed to the unique characteristics of the African Vulture Algorithm; this includes methods for effective search space exploration and exploitation and is modeled after the scavenging behavior of African vultures. In the process of optimizing WEDM parameters like I, WS, and DC using MOAVOA and MOGA techniques, significant outcomes have been observed. In the MOAVOA approach, we achieved a minimum Surface Roughness of 6.25, coupled with a maximum Material Removal Rate of 6.84. Meanwhile, in the MOGA method, the results showed a minimum Ra_CT of 6.32 and a maximum MRR_CT of 6.77. These findings indicate the effectiveness of both optimization methods in enhancing WEDM performance. Specifically, they highlight the balance achieved between Ra_CT and MRR_CT, crucial factors in WEDM operations. The optimal WEDM parameter settings derived from the MOAVOA and the MOGA were selected for validation through confirmation experiments. These experiments were conducted to evaluate the predictive accuracy and reliability of the optimization models in a practical machining environment. The respective optimal parameter sets obtained from each algorithm are summarized in Table 9. Using these settings, separate WEDM trials were performed, and the resulting machining performance characteristics such as MRR_CT and Ra_CT were measured and compared against the predicted values. The confirmation experiments serve to substantiate the effectiveness of both MOAVOA and MOGA in identifying suitable WEDM conditions, with the results offering insight into their comparative performance in real-world applications. A deviation of 1.78% in MRR_CT and 4.14% in Ra_CT was observed when the confirmation experiment was conducted using the optimal parameter settings obtained from MOAVOA. In comparison, the confirmation experiment using the MOGA-derived parameters resulted in deviations of 1.98% in MRR_CT and 4.85% in Ra_CT as shown in Table 9.

Table 9 Results of confirmation experiments.

[ad_2]

Machinability analysis in wire-EDM of cryogenically treated Ti6Al4V alloy and multi-objective optimization using MOAVOA and MOGA