Analytical approach-based optimization of the actively driven rotary turning for environmental and economic metrics considering energy footprint of materials

The current work has been performed an effective optimization to decrease the total energy consumption (E_total) and total machining time (T_total) with the constraint of the average roughness for the actively driven rotary turning (ADRT) of the material labeled SKD11. The optimizing factors are the tool rotational speed (v_t), depth of cut (a), feed rate (f), and workpiece speed (v_w). The analytical approach was used to construct the models of the E_total and T_total. The weightage principal component analysis (WPCA) was applied in conjunction with the non-dominated sorting particle swarm optimization (NSPSO) and the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) to determine the weight values of machining responses and select the best optimal solution. The scientific findings revealed that the optimal values of the v_t, a, f, and v_w were 78 m/min, 0.21 mm, 0.44 mm/rev., and 98 m/min, respectively. The reductions in the E_total and T_total were 16.99% and 17.78%, respectively. Moreover, the proposed models of the E_total and T_total were significant and could be used to predict technical performances with acceptable accuracy. The optimization technique comprising the analytical method, NSPSO, WPCA, and TOPSIS was named as a powerful approach to obtain optimal outcomes.