Optimized XGBoost Model with Small Dataset for Predicting Relative Density of Ti-6Al-4V Parts Manufactured by Selective Laser Melting

Determining the quality of Ti-6Al-4V parts fabricated by selective laser melting (SLM) remains a challenge due to the high cost of SLM and the need for expertise in processes and materials. In order to understand the correspondence of the relative density of SLMed Ti-6Al-4V parts with process parameters, an optimized extreme gradient boosting (XGBoost) decision tree model was developed in the present paper using hyperparameter optimization with the GridsearchCV method. In particular, the effect of the size of the dataset for model training and testing on model prediction accuracy was examined. The results show that with the reduction in dataset size, the prediction accuracy of the proposed model decreases, but the overall accuracy can be maintained within a relatively high accuracy range, showing good agreement with the experimental results. Based on a small dataset, the prediction accuracy of the optimized XGBoost model was also compared with that of artificial neural network (ANN) and support vector regression (SVR) models, and it was found that the optimized XGBoost model has better evaluation indicators such as mean absolute error, root mean square error, and the coefficient of determination. In addition, the optimized XGBoost model can be easily extended to the prediction of mechanical properties of more metal materials manufactured by SLM processes.