Prediction of cutting parameters in band sawing using a gradient boosting-based machine learning approach

Abstract

This study presents a gradient boosting-based machine learning (ML) approach developed to predict cutting speed and feed rate in band sawing operations. The model was built using a dataset of 1701 experimental samples from three industrially common material types: AISI 304, CK45, and AISI 4140. Each sample was defined by key process parameters, namely, material type, a hardness range of 15-44 HRC, and a diameter range of 100-500 mm, with cutting speed and feed rate as target variables. Five ML models were examined and compared in this study, including linear regression (LR), support vector regression (SVR), random forest regression (RFR), least squares boosting (LSBoost), and extreme gradient boosting (XGBoost). Model training and validation were carried out using five-fold cross-validation. The results show that the XGBoost model offers the highest accuracy. For cutting speed estimation, the performance values of XGBoost are an RMSE of 0.213, an MAE of 0.140, an R2 of 0.999, and an MAPE of 0.407%; and for feed rate estimation, an RMSE of 0.259, an MAE of 0.169, an R2 of 0.999, and a MAPE of 1.14%. These results indicate that gradient-based ensemble methods capture the nonlinear behavior of cutting parameters more effectively than linear or kernel-driven techniques, providing a practical and robust approach for data-driven optimization in intelligent manufacturing.