Predictive modelling of residual stress in turning of hard materials using radial basis function network enhanced with principal component analysis

[Display omitted] •The methodology presented has practical implications for manufacturing, offering a feasible way to predict RS in real-time.•Implementing the ML hybrid model PCA-RBFN showed promising results in model simplification and reduced computational cost.•The hybrid method minimizes computational effort by reducing iterations for accurate model training, ensuring robustness.•Machining force signals as inputs for RS modeling can enhance model robustness and predictive accuracy.•The proposed PCA-RBFN enables real-time adaptive ML within the production systems, enhancing operational efficiency. This study proposes a hybrid machine learning (ML) model that combines a radial basis function network (RBFN) with principal component analysis (PCA) to predict residual stress (RS) in the machining process. Higher temperatures and plastic deformation can generate RS conditions in the machining of hard materials, significantly influencing the quality of machined parts, particularly their surface integrity. It is crucial to evaluate and guarantee machining conditions that ensure reliable surface integrity that yields compressive RS conditions. Incorrect parameter settings can lead to poor surface quality, resulting in tensile RS conditions that impact both the quality and lifetime of manufactured products. The methodology involved experimental machining trials for data acquisition, with conditions selected for hard material machining tests conducted using a computer numeric control (CNC) lathe under dry cutting conditions. The cutting force components were measured, and RS was evaluated using X-ray diffraction. A total of 60 trials were conducted. Data preprocessing, including normalization and removal of outliers, was executed before constructing the ML algorithm, leaving 59 valid tests for model training and testing. Separate datasets for training (70 % of the data) and testing (30 %) were randomly selected from the valid experimental tests. PCA enhanced the RBFN model’s generalization by reducing data dimensionality and providing the hidden units parameter. The eigenvectors obtained through PCA served as an efficient initial reference for RBF centroids, highlighting principal directions of variation. The PCA-RBFN model, using a multiquadric radial function, exhibited robust performance in capturing underlying patterns during training and demonstrated balanced results in the tests. In the PCA-RBFN model training stage, it exhibited a coefficient of determina