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DOE OSTI · 3384901

Active learning using hybrid surrogate tool life modeling for machining process optimization

Karandikar, Jaydeep [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000231551214)·Tyler, Christopher [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)]·Olvera Trejo, David [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000300011490)·Brown, Dennis [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)]·Jacobs, Leah [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000256494025)·Smith, Scott [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000258640372)
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Abstract

Here, this paper describes an active learning approach for part-to-part iterative machining process optimization using a hybrid surrogate tool life model. A probabilistic interpolating tool life model is developed by combining the empirical Taylor-type tool life equation and the model fit error. The probabilistic tool life model is then used to calculate the machining cost per part distribution. The optimal machining parameters are selected using an expected improvement in machining cost per part criterion. The method is validated numerically using experimental results; the results show a median convergence error of 2.2% after three tests over 400 simulations. The method is validated experimentally on two industrial applications for Ti-6Al-4V roughing resulting in a cost per part reduction greater than 23% after two tests. The described method is a robust solution for rapid convergence to optimal machining parameters in an industrial production environment.

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Karandikar, Jaydeep [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000231551214), Tyler, Christopher [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)], Olvera Trejo, David [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000300011490), Brown, Dennis [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)], Jacobs, Leah [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000256494025), Smith, Scott [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000258640372). 2026-08-01. Active learning using hybrid surrogate tool life modeling for machining process optimization. https://doi.org/10.1016/j.jmsy.2026.05.009

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