Data-driven optimization of machining parameters for Hastelloy C276 using PSO and TLBO frameworks.
Mosleh M Abualhaj1, B Venkatesh2, Kiran D Parmar3
1Department of Networks and Cybersecurity, Hourani Center for Applied Scientific Research, Al-Ahliyya Amman University, Amman, Jordan.
Scientific Reports
|January 15, 2026
Summary
Cryogenic CO₂ cooling significantly improves Hastelloy C276 machinability, reducing surface roughness and cutting forces. Evolutionary optimization algorithms like Particle Swarm Optimization (PSO) further enhance these sustainable machining strategies.
Area of Science:
- Materials Science
- Manufacturing Engineering
- Sustainable Machining
Background:
- Hastelloy C276 is a high-performance alloy crucial for aerospace and chemical industries.
- Its superior properties present significant machining challenges due to high strength and work hardening.
- Sustainable machining practices are increasingly important to reduce environmental impact.
Purpose of the Study:
- To systematically investigate the machinability of Hastelloy C276 under various sustainable cooling/lubrication methods.
- To analyze the impact of cutting parameters on surface roughness, cutting force, tool wear, and temperature.
- To optimize machining conditions using advanced computational algorithms.
Main Methods:
- Experiments conducted using a Taguchi L16 orthogonal array.
- Four environments tested: dry machining, minimum quantity lubrication (MQL), nano-enhanced MQL (NMQL), and cryogenic CO₂ (CCO₂).
- Analysis of Variance (ANOVA) used to determine parameter significance; Particle Swarm Optimization (PSO) and Teaching-Learning-Based Optimization (TLBO) for optimization.
Main Results:
- Cryogenic CO₂ cooling reduced surface roughness and cutting force by 30-40% compared to dry machining.
- Significant reductions in tool wear and cutting temperature observed with cryogenic CO₂.
- Feed rate and cutting speed were identified as the most influential parameters for surface roughness and temperature.
- PSO achieved a higher optimization success rate (83.6%) than TLBO (79.1%).
Conclusions:
- Cryogenic CO₂-assisted machining offers an effective and sustainable strategy for improving Hastelloy C276 machinability.
- NMQL provides moderate benefits through enhanced lubrication.
- Evolutionary optimization algorithms are valuable tools for determining optimal machining parameters for challenging alloys.
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