The Use of a Radial Basis Function Neural Network and Fuzzy Modelling in the Assessment of Surface Roughness in the MDF Milling Process.

Wood-based composites are increasingly used in the industry not only because of the shortage of solid wood, but above all because of the better properties, such as high strength and aesthetic appearance compared to wood. Medium-density fiberboard (MDF) is a wood-based composite that is widely used in the furniture industry. In this work, an attempt was made to predict the surface roughness of the machined MDF in the milling process based on acceleration signals from an industrial piezoelectric sensor installed in the cutting zone. The surface roughness parameter Sq was adopted for the evaluation and measurement of surface roughness. The surface roughness prediction was performed using a radial basis function (RBF) artificial neural network (ANN) and a Takagi-Sugeno--Kang (TSK) fuzzy model with subtractive clustering. In the research, as inputs to the ANNs and fuzzy model, the kinematic parameters of the cutting process and selected measures of the acceleration signal were adopted. At the output, the values of the surface roughness parameter Sq were obtained. The results of the experiments show that the surface roughness is influenced not only by the kinematic parameters of the cutting, but also by the vibrations generated during the milling process. Therefore, by combining information on the cutting kinematics parameters and vibration, the accuracy of the surface roughness prediction in the milling process of MDF can be improved. The use of TSK fuzzy modelling based on the subtractive clustering method for integrating the information from many acceleration signal measurements in the examined range of cutting conditions meant the surface roughness was predicted with high accuracy and high reliability. With the help of two tested artificial intelligence tools, it is possible to estimate the surface roughness of the workpiece with only a small error. When using a radial neural network, the root mean square error for estimating the value of the Sq parameter was 0.379 μm, while the estimation error based on fuzzy logic was 0.198 μm. The surface of the sample made with the cutting parameters v = 76 m/min and v = 1200 mm/min is characterized by a less concentrated distribution of ordinate densities, compared to the surface of the sample cut with lower feed rates but at the same cutting speed. The most concentrated distribution of ordinate density (for the cutting speed v = 76 m/min) is characterized by the surface, where the feed rate value was v = 200 mm/min, with 90% of the material concentrated in the profile height of 28.2 μm. When using an RBF neural network, the RMSE of estimating the value of the Sq parameter was 0.379 μm, while the estimation error based on fuzzy logic was 0.198 μm.