Proceedings of the International Conference on Advanced Engineering Optimization Through Intelligent Techniques

(AEOTIT), J uly 01-03, 2013

S.V. National Institute of Technology, Surat 395 007, Gujarat, India
11

Multi-objecti ve Optimizati on for Milli ng Operation by Usi ng
Geneti c Al gorithm

A. Gjelaj
1*
, J . Balic
2


1
Faculty of Technical Applied Sciences of Mitrovica University of Prishtina, Kosova
2
Faculty of Mechanical Engineering of Maribor University of Maribor, Slovenia

*Corresponding author (e-mail: afrim.gjelaj@uni-pr.edu)

This paper presents the analysing of cutting power as well as cutting force by end
milling process. Analysing of results is obtained for cutting power and cutting force in
theoretical and experimental is achieved. To achieve the best value of cutting power
also cutting force is utilization the multi objective genetic algorithm as optimized
method. Also in our work paper will be optimized the main machining parameters for
cutting power Pc, cutting force Fc and material removal rate MMR by end milling
operation.

1. Introduction

Nowadays, artificial intelligence in manufacturing has wide applications. Therefore
their application by metal cutting has biggest influence such us: to optimize cutting
parameters, expression, and in same time to minimize the errors. In our work paper for cutting
power, cutting force and material removal rate by end milling operation are investigated. Also,
is applied the artificial intelligence such us Multi-objective Genetic Algorithm to find the best
solution of optimal machining parameters.
YAO Yunping et al. (2010) proposed the online optimal machining parameters for
OPTIMILL control machine tools. The proposed system could short the working time as well
as to protect milling tools in same time reduce the cost of production and raising production.
H. Ganesan et al. (2011) discussed about the optimization of machining parameters for
continues profile machining with respect to reduce the time, cutting force, and cutting power
by turning operation. Also the authors due to the complexity of machining have made the
comparing of results obtained in environments of Genetic Algorithm as well as Particle Swarm
Optimization. M. J anardhan and A. Gopala Krishna (2012) present the multi objective
optimization of cutting parameters for response surface roughness and metal removal rate by
grinding operation. In our work the cutting force, cutting power and material removal rate to
end milling operation for workpiece material 42CrMo4 are investigated. Also the selection of
tool with four teeth and diameter (d =8 mm) are used to achieved the optimal results for
cutting force, cutting power and material removal rate. Three conflicting objectives, cutting
force (Fc), cutting power (Pc) and material removal rate (MRR), are simultaneously optimized.

2. Analytical model for cutting power and cutting force by end milling

Many authors are oriented for optimal surface roughness, tool wear, cutting force
machining parameters, tool geometry etc. In our paper will analysed expect cutting force (Fc),
cutting power (Pc) and material removal rate (MRR) due to the important of machining
process will investigated the main of machining parameters (v, f and a). The machining
parameters play an important role for optimization and determination of the cutting power,
cutting force as well as material removal rate by end milling operation. Therefore, in order to
optimization cutting power Pc and material removal rate MRR by end milling process,
respectively workpiece material and tool geometry will get in this case as constant. The main
machining parameters such as depth of cutting, feed rate and cutting speed will optimization
by employing Genetic Algorithm. Cutting Power Pc for milling operation can be expressed in
function of cutting force Fc as follow.
Proceedings of the International Conference on Advanced Engineering Optimization Through Intelligent Techniques
(AEOTIT), J uly 01-03, 2013
S.V. National Institute of Technology, Surat 395 007, Gujarat, India
12

|
|
.
|

\
|
=
0
360

Z v F P
c c
. (1)
Where, Z number of teeth (Z=4), - helix angle ( =30)
The cutting force F
c
is given with expression as follow:
3 2 1
a f v b F
c
= .

(2)
Exponent of cutting force |
1
, |
2,
|
3
and b are constant in our investigation of cutting
power Pc and cutting force Fc. The material removal rate (MRR) can be expressed in
analytical form in function of the cutting speed (v), depth of cut (a) and feed rate (f) as follow:
a f v MRR =1000 (3)
There are several factors constrains of cutting parameters feed rate, cutting speed,
depth of cut, workpiece material, tool geometry, coolant system etc. In our work will take only
the main parameters as constrains.
As procedure of optimal constrains are presented as follow:
max min
max min
max min
a a a
f f f
v v v
< <
< <
< <


(4)
The constrains in these case are given to analyze the cutting force Fc, cutting power
Pc as well as material removal rate MRR.

Table 1. The results of main cutting force Fc without optimization

No. of
Experiment
Main cutting parameters Cutting force Fc
v
[m/min]
f
[mm/rev]
a
[mm]
Measurement
value
Theoretical
value
1 10 0.65 0.8 3.31 3.55
2 15 0.65 0.8 2.83 4.099
3 12 0.4 0.5 3.79 3.482
4 12 0.4 0.5 3.04 3.482

The main of cutting force Fc for theoritical and practical procedure also for feed rate
(f) is presented in figure 1.

Figure 1. Various value of main cutting force (Fc) in relationship of feed rate (f).

The cutting power (Pc) as well as depth of cut (a) is possible to determine the value of
volume for material removal rate (MRR). In table 2 the cutting power Pc based on the
obtained results of cutting force (Fc) regarding to the cutting speed (v) and helix angle () is
calculating wit mathematical expression of cutting power for Pcmax, Pcmean and Pcmin.
Proceedings of the International Conference on Advanced Engineering Optimization Through Intelligent Techniques
(AEOTIT), J uly 01-03, 2013
S.V. National Institute of Technology, Surat 395 007, Gujarat, India
13

Table 2. Obtained results for cutting power Pc

Cutting
speed v
[m/min]
Number
of teeth
Z
Helix
angle
[]
Measurement
of cutting
force Fc [N]
Cutting power Pc [kW]
Pc
max
Pc
mean
Pc
min
12 4 30 3.31 16.55 13.24 11.033
15 4 30 2.83 14.15 11.32 9.433
10 4 30 3.79 18.95 15.16 11.607
12 4 30 3.04 15.20 12.16 10.133

In figure 2 is presented the cutting power Pc respect to the cutting force and cutting
speed. With minimal of cutting value and maximal of feed rate and depth of cut will reach the
maximum of cutting power as in figure 2. With increased of the cutting speed will decreased
the cutting power.

Figure 2. Cutting power Pc in function of cutting speed v and cutting force Fc


3. Multi objective optimization problem by machining using genetic algorithm

Being a population based approach, Genetic Algorithm are well suitable to solve
multiobjective optimization problem. To find the optimal solution for treated problem the
multi-objective optimization problem using Genetic Algorithms are employed. This is a very
popular problem in practice and can be written in the following form:
{ } 0
; 2 ;
) (
) (
) (
) ( min
2 1
2
1
s =
>

=
T
n
obj
nobj
x x x x
n
x f
x f
x f
x f

(3)
The number of function required to be minimal two n
obj
>2, never then less.
subjected to the constraints:
{ } 0 ) ( ) ( ) ( ) (
2 1
s =
T
nc
x g x g x g x g . (4)
where scalar functions f(x) and g(x) are termed the multi objective and constraint
function, respectively. The vector x denotes variables. The symbol (n) denotes the number of
variables, and (n
c
) is the number of constrains. In many case of real problems, multi
objective optimization problem involving multiple and conflicting objectives. Hence, optimizing
of the machining variables with respect to a single objective function often results in
Proceedings of the International Conference on Advanced Engineering Optimization Through Intelligent Techniques
(AEOTIT), J uly 01-03, 2013
S.V. National Institute of Technology, Surat 395 007, Gujarat, India
14

unacceptable results with respect to the other objectives functions. Therefore, a perfect multi
objective solution that simultaneously optimizes each objective function is almost impossible
by Konak Abdullah et al. (2006). A reasonable solution to a multi objective problem is to
investigate a set of solutions, each of which satisfied the objectives at an acceptable level
without being dominated by any other solution. The definition of optimal cutting parameters
plays an important role in metal cutting process. In this work is present a multi-objective
optimization technique, based on genetic algorithms, for optimizing the cutting parameters by
milling process. The cutting force is including in cutting power. So in our case two objectives
function: cutting power Pc and material removal rate MMR are suggested to optimise.

Figure 3. Diagram of Genetic Algorithm process

The first multi objective GAs, called vector evaluated GAs, was proposed by
Schaffer (1995). Afterwards several multi objective evolutionary algorithms were developed
including Multi objective Genetic Algorithms (MOGAs). Clearly, the above optimization
process is a nonlinear programming problem. Optimization procedure in GAs, starts by
reading the boundary of variables and initialize machining parameters: f, a, v. Furthermore,
the main machining parameters are passed into the milling operation to find near more near
optimal solutions of cutting power Pc and material removal rate MRR. These values are
substituted into GAs process to calculate fitness function - objective function.
The optimization results for two objective function as cutting power and material
removal rate and are shown in figure 4. Also the optimal machining parameters cutting speed
(v), feed rate (f) and depth of cut (a) are obtained from the Pareto front graph. After
optimization of the objective function are reached the optimal machining parameters.
Proceedings of the International Conference on Advanced Engineering Optimization Through Intelligent Techniques
(AEOTIT), J uly 01-03, 2013
S.V. National Institute of Technology, Surat 395 007, Gujarat, India
15


Figure 4. Pareto front solutions for cutting power Pc and material removal rate MRR.

4. Conclusion

This paper presents Multiobjective Genetic Algorithm (MOGA) optimization for solving
the problem of machining operations by end milling process. The obtained results of cutting
force in experimental way are used by expression of cutting power Pc. Material removal rate
MRR, cutting power Pc and main machining parameters are optimized in environment of
Matlab such as Genetic algorithm. The optimization results are plotted as Pareto optimal
front. This paper also remarks the advantages of multi-objective optimization approach over
the single-objective one.

Acknowledgement

The author is profoundly grateful to Professor J oze Balic.

References

Abdullah, K., David, C. and Alice, S. Multi-objective optimization using genetic algorithms: A
tutorial, Reliability Engineering and System Safety. 2006, 91 9921007.
Ganesan, H. Optimization of machining parameters in turning process using genetic algorithm
and particle swarm optimization with experimental verification. International Journal of
Engineering Science and Technology, 2011, 3(2), 1092-1102.
J anardhan, M. and Krishna A.G. Multi-objective optimization of cutting parameters for surface
roughness and metal removal rate in surface grinding using response surface
methodology. International Journal of Advances in Engineering & Technology, 2012, 3 (1)
270 283.
Schaffer, J .D. Multi-objective optimization with vector evaluated genetic algorithms. In Genetic
Algorithms and Their Applications. Proceedings of the First International Conference on
Genetic Algorithms, 1985, 93-100.
Yunping, Y. Optimize CNC Milling Parameters On-line. International Conference on
Measuring Technology and Mechatronics Automation, 2010, 856 859.
400 600 800 1000 1200 1400 1600 1800 2000
1610
1620
1630
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1660
1670
1680
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Cutting power Pc
M
a
t
e
r
i
a
l

r
e
m
o
v
a
l

r
a
t
e

M
R
R
Population size: 100
Number of generations: 103
Selection strategy: Tournament
Crossever probability: 0.7