Prediction of feed force with machine learning algorithms in boring of AISI P20 plastic mold steel

Feed force plays a critical role in machining performance, including efficiency, hole quality, energy consumption, and tool life. While feed force is typically measured using dynamometers, these devices are often impractical in real-world experiments due to their complexity and cost. In particular, boring operations, which are essential for enlarging holes within tight tolerances, depend on precise feed force control to maintain high-quality hole outcomes. Achieving this precision requires reliable pre-process feed force estimation. However, traditional analytical methods for calculating feed force in boring operations often fall short, largely due to factors such as in-hole dynamics, the inclination of the rake surface, and the slenderness of the boring bar. This study aims to apply single and hybrid machine learning methods to accurately model and predict feed force in the boring process. Unlike previous research, which focused on feature selection, we propose the use of all possible combinations of input feature subsets to determine the optimal input features. The results indicate that feed force can be predicted effectively using these optimized feature combinations. Such accurate feed force prediction is crucial for effective process optimization, material selection, and process planning. [Display omitted]