Int J Adv Manuf Technol (2007) 32: 644655
DOI 10.1007/s00170-005-0384-3
ORIGINA L ARTI CLE
P. Palanisamy . I. Rajendran . S. Shanmugasundaram
Optimization of machining parameters using genetic algorithm
and experimental validation for end-milling operations
Received: 28 July 2005 / Accepted: 27 December 2005 / Pulished online: 19 April 2006
# Springer-Verlag London Limited 2006
Abstract Optimization of cutting parameters is valuable
in terms of providing high precision and efficient
machining. Optimization of machining parameters for
milling is an important step to minimize the machining
time and cutting force, increase productivity and tool life
and obtain better surface finish. In this work a mathemat-
ical model has been developed based on both the material
behavior and the machine dynamics to determine cutting
force for milling operations. The system used for
optimization is based on powerful artificial intelligence
called genetic algorithms (GA). The machining time is
considered as the objective function and constraints are
tool life, limits of feed rate, depth of cut, cutting speed,
surface roughness, cutting force and amplitude of vibra-
tions while maintaining a constant material removal rate.
The result of the work shows how a complex optimization
problem is handled by a genetic algorithm and converges
very quickly. Experimental end milling tests have been
performed on mild steel to measure surface roughness,
cutting force using milling tool dynamometer and vibration
using a FFT (fast Fourier transform) analyzer for the
optimized cutting parameters in a Universal milling
machine using an HSS cutter. From the estimated surface
roughness value of 0.71 m, the optimal cutting parameters
that have given a maximum material removal rate of
6.0103 mm3/min with less amplitude of vibration at the
P. Palanisamy
Department of Mechanical Engineering,
Kumaraguru College of Technology,
Coimbatore, Tamil Nadu, 641006, India
e-mail: ppalanisamy2003@yahoo.com
I. Rajendran (*)
Department of Mechanical Engineering,
Bannari Amman Institute of Technology,
Sathyamangalam, Tamil Nadu, 638401, India
e-mail: irus_rajendran@yahoo.co.in
Tel.: +91-4295-221289
Fax: +91-4295-223775
S. Shanmugasundaram
Government College of Technology,
Coimbatore, Tamil Nadu, 641013, India
work piece support 1.66 m maximum displacement. The
good agreement between the GA cutting forces and
measured cutting forces clearly demonstrates the accuracy
and effectiveness of the model presented and program
developed. The obtained results indicate that the optimized
parameters are capable of machining the work piece more
efficiently with better surface finish.
Keywords Genetic algorithms . Milling . Cutting force .
Surface roughness . Tool life . Machining time
Nomenclature
A Cross-sectional area of chip (mm)
b Axial depth of cut (mm)
br Radial depth of cut (mm)
D Diameter of cutting tool (mm)
L Length of work piece (mm)
FN Radial force (N)
FT Thrust force (N)
f Feed rate per tooth (mm/tooth)
fW Table feed rate (work piece feed rate), mm/min
Fx, y Cutting force component in directionx andy (N)
h Chip thickness (mm)
k Stiffness of the cutter (N/mm)
m Average number of teeth in contact with work piece
N Rotational speed of milling cutter (rpm)
Ra Value of surface roughness (m)
T Tool life (min)
V Cutting speed (m/min)
x Dynamic displacement in feed direction x (mm)
y Dynamic displacement in normal direction y (mm)
Z Number of teeth on the cutting tool
Rotational position of cutting edge (degrees)
1 Introduction
The milling operation is a metal cutting process using a
rotating cutter with one or more teeth. The determination of
optimal cutting parameters such as depth of cut, cutting
speed and feed, which are applicable for assigned cutting

tools, is one of the vital modules in process planning of
metal parts, since the economy of machining operations
plays an important role in increasing productivity and
competitiveness. The purpose of this study is to investigate
the optimal cutting parameters for minimizing machining
time and maximizing surface finish of the milling operation
while maintaining material removal rate and stability of the
cutting process. The main parameters in machining
affecting machining time and surface finish are cutting
speed, feed per tooth, and axial depth. The optimal cutting
parameters are subjected to an objective function of
minimum machining time with the feasible range of
cutting parameters. The user of the machine tool must
know how to choose cutting parameters in order to
minimize cutting time, cutting force and produce better
surface finish under stable conditions. Normally, feed rate,
cutting speed, depth of cut and axial immersion are chosen
according to the technical guide. But these parameters are
strongly dependent on the dynamic properties of the tool,
as well as spindle. In order to obtain better surface
roughness, the proper setting of cutting parameters is
crucial before the process takes place.
This paper introduces a computer algorithm developed
to optimize the cutting parameters for minimizing machin-
ing time and maximizing tool life for a constant material
removal rate. The system is mainly based on a powerful
artificial intelligence (AI) tool, called genetic algorithms
(GAs). With the use of GAs, the impact and the power of
AI techniques have been reflected on the performance of
the optimization system. The methodology of the devel-
oped optimization system is illustrated with practical
examples throughout the paper. Optimization of machining
parameters not only increases the utility for machining
economics, but also the product quality to a great extent. In
this context, an effort has been made to estimate the surface
roughness and cutting force using experimental data.
2 Literature survey
Tolouei-Rad and Bidhendi [1] described the development
and utilization of an optimization system which determines
optimum machining parameters for milling operations.
These parameters are intended for use on NC machines;
however, they can also be used for conventional machines.
Choudhury and Rao [2] presented a new approach for
improving cutting tools by using optimal values of velocity
and feed throughout the cutting process. Suresh et al. [3]
developed a second order mathematical model in terms of
machining parameters for surface roughness prediction
using response surface methodology. An attempt has been
made to optimize the surface roughness using genetic
algorithms. Sonmez et al. [4] developed an optimization
strategy to determine cutting parameters for multipass
milling operations like plain and face milling for
maximizing production rate. Kim and Ramulu [5]
optimized the drilling process of machining graphite/
bismaleimide-titanium alloy stacks by taking hole quality
and machining cost as objective functions. Wang et al. [6]
645
optimized cutting conditions (feed and speed) in plain
milling taking production time as an objective function.
Dereli et al. [7] optimized cutting parameters for milling
operations taking unit cost as an objective function by
using genetic algorithm. Juan et al. [8] optimized cutting
parameters for minimizing production cost on the rough
machining of high speed milling operations. A machining
model is constructed based on a polynomial network.
Tandon et al. [9] optimized the tool path for end milling
using a new evolutionary computation technique. Baek et
al. [10] optimized the feed rate in terms of providing high
precision and efficient machining. Shunmugam et al. [11]
optimized the machining parameters such as number of
passes, depth of cut in each pass, and speed and feed
obtained using a genetic algorithm (GA), to yield minimum
total production cost while considering technological
constraints such as allowable speed and feed, dimensional
accuracy, surface finish, tool wear and machine tool
capabilities in face-milling operations.
Closer study of the above works reveals that there has
been substantial evidence to support the view that surface
finish and tool life can be improved by optimizing the
cutting parameters. Some researchers optimized machining
parameters based on a single variable by considering a
single constraint. However, it is obvious that the real
optimal parameter cannot be achieved without considering
all the variables and constraints simultaneously. In the
present work, efforts have been made to study the influence
of feed, depth of cut and cutting speed during machining on
the tool life and surface finish while minimising the
machining time.
3 Modelling
Milling is a metal cutting process in which the cutting tool
intermittently enters and leaves the work piece, unlike
turning, in which the tool is always in contact. In the
milling process, material is removed from a work piece by
a rotating cutting tool. While the tool rotates, it translates in
the feed direction at a certain speed. A milling process can
be modeled as cutting simultaneously with a number of
single-point cutting tools (with the tool having only one
major cutting edge). A basic dynamic model of 2-DOF end
milling with a flexible tool is illustrated in Fig. 1. This
model is dynamic in the sense that the effect of tool and
work piece vibrations on the instantaneous tooth feed is
considered, and the part is assumed to be rigid. The chip
thickness during machining periodically varies due to the
vibration of the machine structure and cutting tool. The
cutter is assumed to have z number of teeth and zero helix
angle. Since stability is determined by the average effect
during one revolution, the helix angle is ignored. If the tool
is flexible, its motion in both the x and y directions affects
the chip load and cutting forces, leading to chatter
instability under certain conditions. The process param-
eters are the spindle speed N, the feed per tooth (chip load)
f, the radial depth-of-cut br and the axial depth of cut b. In
development of a dynamic force model for end milling, the
646

objective of this study is to combine the concept of the and resultant force in the y direction
equivalent orthogonal cutting conditions with the concept
of a regenerative force model to predict the cutting force. X
z
Fy FTi sin i
FNi cos i (4)
i
1

3.1 Determination of cutting force

The tooth of a milling cutter can be viewed as a single point Substitution of Eqs. 1 and 2 into Eqs. 3 and 4 yields x
tool referring to a rotating coordinate system; hence, the and y cutting forces, each with three distinct terms: depth of
cutting force in milling can be calculated from a predictive cut b, sine and cosine of . Equations 5 and 6 can be
force model as presented in Fig. 1 from cutting conditions, rewritten as
the property of the work material, the tool geometry and the
corresponding instantaneous dynamic re-generative unde- X
z
1
formed chip thickness. Consider the case of up milling with Fx Ks bf sin i cos i 0:3 sin2 i Ks bf
i
1
2
an assumed circular tool path. The cutter is subjected to (5)
normal and tangential cutting force components which may X
z

be projected into x and y coordinate directions using  sin 2i 0:3
0:3 cos 2i
i
1
rotational positioning of cutting edge .
1. The tangential force FT is proportional to the material
dependent specific force Ks, the feed per tooth f, the X
z
1
chip width b, and the rotational position of cutting edge . Fy Ks bf sin2 i
0:3 sin i cos i Ks bf
i
1
2
(6)
FT K s bf sin (1) X
z
 1
cos 2i
0:3 sin 2i
i
1
2. The normal radial force is assumed proportional to
tangential force FN
Where z is the number of teeth on the cutter. The x and
FN kt FT (2) they cutting force components given in Eqs. 5 and 6 may be
evaluated analytically for the optimized cutting parameters
where kt is the cutting force coefficient. Resolving FT and compared with measured values.
and FN into cutting forces in the x andy direction and
summing for all the teeth engaged will result in
4 Optimization
X
z
Fx FTi cos i FNi sin i (3)
4.1 Working principle of GA
i
1

The genetic algorithm (GA) is a population-based search

optimization technique and has been used as a powerful
tool for optimizing cutting parameters in end milling
operations. The data processed by GA includes a set of
strings (or chromosomes) with an infinite length in which
each bit is called an allele (or a gene). A selected number of
strings are called a population and the population at a given
time is a generation. Generation of the initial population of
strings is done randomly. Since the binary alphabet offers
the maximum number of schemata per bit of information of
any coding, a binary encoding scheme is traditionally used
to represent the chromosomes using either zeros or ones.
Thereafter, the fitness value (objective function value) of
each member is computed. The population is then operated
by the three main operators, namely, reproduction, cross-
over, and mutation to create a new population. The new
population is further evaluated and tested for determina-
tion. One iteration of these three operators is known as a
generation in the parlance of GA. The range of cutting
parameters variables are given in Table 1.

Fig. 1 Dynamic model of end milling (2-DOF)

 647
Table 1 Cutting parameters 4.2.3 Basic operators of GA
Sl No Cutting parameters Range of values

1 Max and min bound feed/tooth, f 0.050.3 mm/tooth

1. Reproduction
Reproduction is the first operator applied on a
2 Max and min bound depth of cut , b 0.52.5 mm
population. In this process individual strings are copied
3 Max and min bound cutting speed, V 2040 m/min
into a separate string called the mating pool
according to their fitness values, i.e. the strings with
4.2 Implementation of GA a higher value have a higher probability of contributing
one or more offspring in the next generation. A
4.2.1 Coding reproduction operator can be implemented in algo-
rithmic form in a number of ways. The easiest way is to
In order to use GAs to solve the problem, variables xis are create a biased roulette wheel where each current string
first coded in some string structures. Binary-coded strings in the population has a roulette-wheel-slot-size in
having ones and zeros are primarily used. The length of the proportion to its fitness. In this way more highly fit
string is usually determined according to the desired strings have higher numbers of offspring in the
solution accuracy. In order to solve this problem using GA, succeeding generation. Once the string has been
binary coding is chosen to represent the variables f,b andV selected for reproduction an extra replica of the string
as given in Table 2. In the calculation here, 8 bits are is made. The string is then entered into the mating pool,
chosen for f,b andV and thereby making a total string length a tentative new population for further genetic operator
of 24. With the coding, the solution accuracy obtained in action.
the given interval for f,b andV are 0.001 mm/tooth, 2. Crossover
0.01 mm and 0.1 m/min, respectively. After reproduction, the population is enriched with
good strings from the previous generation but does not
have any new string. A crossover operator is applied to
4.2.2 Fitness function the population to hopefully create better strings. The
total number of participative strings in crossover is
GAs mimic the survival of the fittest principle. So, controlled by crossover probability, which is the ratio
naturally they are suitable to solve maximization problems. of total strings selected for mating and the population
Maximization problems are usually transformed to mini- size. The crossover operator is mainly responsible for
mization problems by some suitable transformation. A the search aspects of GA. In order to perform
fitness function F(x) is derived from the objective function crossover, a random number is generated between 1
and is used in successive genetic operations. For and 7. If the random number is 5, the bits after the 5th
maximization problems, fitness function can be considered position are exchanged as given below in the following
the same as the objective function. The minimization example.
problem is an equivalent maximization problem such that
the optimum point remains unchanged. A number of such Example : String 1
11001101
transformations are possible. The fitness function often String 2
01110100
used is
Crossover probability = 0.9
1
F x ; (7) New string (offspring 1) - 11001100
1 f x New string (offspring 2) - 01110101
3. Mutation
Mutation, as in the case of simple GA, is the occasional
The independent variables for optimal cutting param- random alteration of the value of a string position. This
eters have been identified as the following: tool diameters means changing 0 to 1 or vice versa on a bit by bit basis
and length, spindle speed, and feed per tooth.
Table 2 Solution accuracy for feed/tooth, depth of cut and cutting speed
Feed Code Decode f Range Accuracy
(0.05 to 0.3 mm/tooth) 00000000 0 0.05 0.25 0:25=255 0:00098=0.001
11111111 255 0.30
Depth of cut Code Decode b Range Accuracy
(0.5 to 3.0 mm) 00000000 0 0.5 2.5 2:5=255 0:0098=0.01
11111111 255 3.0
Cutting speed Code Decode V Range Accuracy
(20 to 40 m/min) 00000000 0 20 20 20=255 0:078=0.1
11111111 255 40
648
and with a small mutation probability of 0.001 to 0.05.
The need for mutation is to keep diversity in the
population.
Example: String 1 11001101
String 2 01110100
Mutation probability =0.001
New string (offspring 1) -01001101
New string (offspring 2) -01110110
After applying the GA operators, a new set of
population is created. Then, they are decoded and
objective function values are calculated. This com-
pletes one generation of GA. Such iterations are
continued till the termination criterion is achieved. The
above process is simulated by a computer program
with a population size of 25, iterated for 200
generations and crossover and mutation probability
are selected to be 0.9 and 0.001, respectively.
4.3 Objective function
4.3.1 Minimize the machining time
The objective function is to minimize the machining time.
It has also been found that minimizing the machining time
is the most effective objective in order to utilize the
machine more effectively.
The machining time, tm, is defined as:


LD w Zl
tm minutes (8)
1000VZf br
4.3.2 Unit time
The unit time to produce a part in a milling operation can be
defined by
Tu ts tm tch tm =T (9)
The unit time is the sum of set-up, machining and tool
changing times. In single tool milling operations only a
worn tool needs to be changed. Hence, tool changing time
for each part is calculated based on the machining time of
the part compared to the tool life. Set-up and tool changing
times are not influenced by machining parameters, and can
be excluded from the equation for optimization purposes.
Therefore, the optimization model for the minimum pro-
duction (unit) time in milling operations becomes Tu tm .
4.4 Constraints
In practice, possible ranges for cutting speed and feed rate
are limited by the following constraints:
1. Surface finish requirements; for the milling process the
surface roughness range is 0.8 to 6.3 m (see Lindberg
[12])
2. Tool life; minimum expected tool life for an HSS tool
is 60 to 120 min (see Nagpal [13])
3. Maximum cutting force permitted by the rigidity of the
tool; maximum cutting force is limited to 500 N (see
Toh [14])
4. Amplitude of vibration at the work piece holder; for
stable cutting the maximum amplitude of vibration is
limited to 2 m (see Lacerda and Lima [15])
5. Maximum heat generated by cutting
6. Available feed rates and spindle speeds on the machine
tool
Excessive heat generation can be overcome by the use of
efficient coolants. Also, modern NC and CNC machines
are not faced with the last constraint since they provide all
possible feed rates and spindle speed within an acceptable
range. Therefore, the first four constraints are considered in
this work.
4.4.1 Surface roughness
Ra is the most commonly used parameter to describe the
average surface roughness and is defined as an integral of
the absolute value of the roughness profile measured over
an evaluation length:
Ra 1=l jz xjdx (10)
0
The average roughness is the total area of the peaks and
valleys divided by the evaluation length; it is expressed in
m (thousandths of a millimeter). The arithmetic value of
surface roughness in end milling can be represented by:
 
Ra 318 f 2 4D (11)
The required surface finish value should be smaller than
or equal to the maximum achievable surface finish under
the existing machining conditions.
4.4.2 Tool life
Tool life (T) can be defined as a tools useful life until it no
longer produces satisfactory parts. When the wear reaches
a certain value the tool is not capable of further cutting
unless it is resharpened. This is because increased
bluntness of the cutting edge causes an increase in cutting
forces and as a result tool temperature also increases.
Consequently both dimensional accuracy and surface
finish of the machined piece suffer, ultimately leading to
the production of rejects. Life of the tool is affected by
 649

various parameters such as cutting speed, feed, depth of dynamics (tools transfer function)such that
cut, chip thickness, tool geometry and cutting fluid.
A corrected empirical formula for the practical tool life T 1 1
r2
of a cutting tool to be used in end milling operations has ReG (16)
k 1
r2 2r2
been proposed by Tolouei-Rad and Bidhendi [1]:

2  g 31n If machining is done in a manner such that b<blim min, the

Cv 5fd system is stable or the amplitude of vibration is within a
T 4 5 60 minutes (12)
V df z safe limit. Using Eq. 15 and stiffness of the system, the
limiting depth of cut is 1.38 mm for mild steel work piece
material but the optimized depth of cut is only 0.92 mm, so
where Cv is the constant for 60 min tool life when the area it is under a stable condition. It is also verified
of cut is 1 mm2, the slenderness ratio G= (d/f) = 5, and g,z experimentally by measuring the amplitude of vibration
and n are constants for different tool-work combinations. by using a FFT (fast Fourier transform) analyser.
The material removal rate for the optimized value in
milling is the volume of material removed by the cutter per
unit time
4.4.3 Cutting force 
MRR fw bbr mm3 min (17)
The cutting force equations derived from the model in the x
and y directions are given by
Here, fw is the work piece (table) feed mm/min given by
Fx FT cos FN sin (13)
fw fzN (18)
and

FY FT sin
FN cos (14) b is the depth of cut, br is the radial depth of cut, N is the
spindle speed, and f is the feed/tooth.
The stability mainly depends upon depth of cut b which
4.4.4 Amplitude of vibration (stability) is directly proportional to the material removal rate.

The problem of stability analysis is often reduced to

determining the maximum limiting depth of cut bmin at
which chatter will not occur. The allowable minimum
depth of cut for milling operation is limited by process
variables of specific cutting energy U and system dynamics
G [16]:

1
blim
2k :m:ReG
Here, k is the cutting stiffness (N/mm), is the direction
orientation factor, r is the damping ratio (/n), m is the
average number of teeth in contact with the work piece =
(z*br)/ (2*D), and Re[G()] is the real part of system
5 Experimental studies
The milling operation was carried out on a STAR MILL-
ATC Universal milling machine on mild steel work piece
material using an HSS tool. Cutting forces and vibration
have been measured and monitored by using a three-
component milling tool dynamometer and a DI-2200 twin
(15)
channel FFT (fast Fourier transform) analyzer with
pickups. The purpose of the experiment is to validate the
optimized parameters during an end milling operation. The
experimental setup is shown in Fig. 2, while Fig. 3 shows a
photograph of the experimental set up. The work piece is
a block of 1205010 mm. The tests are conducted along a
120 mm edge. The work piece is firmly held on a specially
designed vice (with sensors to measure the forces in the x, y

Table 3 Specifications of Universal milling machine, cutter and work piece material
Sl No Parameters Value Sl No Parameters Value

1 Power 5.5 KW 8 Spindle speed ranges 31.5 to 2,000 rpm

2 Efficiency 0.7 9 Table feed rate ranges fw 14900 mm/min
3 Diameter of cutter 20 mm 10 Work piece material Structural carbon steel (C<0.6%),
4 Number of teeth 6 11 Tensile strength 750 MPa
5 Material of cutter HSS 12 Brinell Hardness 90 BHN
6 Bending strength for cutter material 140 MPa 13 Size of work piece 1205010 mm
7 Youngs modulus 200 GPa 14 Radial depth of cut 20 mm
650

measurement using a surface tester for the optimized

cutting parameters (Fig. 4).

6 Results and discussion

Spindle It is believed that a large generation size helps in better
schema processing and thus reduces the changes of
work piece Accelerometer premature convergence. Therefore, the generation size in
Sensor this optimization is selected as 200, and crossover and
mutation probability are selected to be 0.9 and 0.001,
respectively.

6.1 Cutting parameters and objective function

3 Axis Milling Tool
Dynamometer
Printer Computer FFT Analyzer
DI-2200
Fig. 2 The experimental set up
and z directions) on the machine. The sensors are
connected to a force indicator to displace the force values.
An accelerometer pick up with magnetic base is attached to
the work piece holder (vice) to sense the vibration. The
signal absorbed by the accelerometer pick up is transferred
to the FFT analyzer. The FFT analyzer is interfaced with a
computer for vibration analysis in polymate software. The
cutter has been made using a 6-teeth, 20 mm diameter
cutter mounted in a shrink-fit tool holder. Table 3 shows the
specifications of the milling machine, cutter and work
piece material for this work. The experimental tests consist
of three parts: (1) determination of cutting force using
milling tool dynamometer, (2) vibration measurement
using the FFT analyzer, and (3) surface roughness
Optimization has been performed using GA to decide the
best possible combination of feed, cutting speed and depth
of cut by satisfying constraints including tool life, surface
roughness, cutting force and amplitude of vibration.
During the process of searching for the optimum, the
variation of cutting parameters feed/tooth, cutting speed
and depth of cut in each generation are shown in Figs. 5, 6
and 7, respectively. It has been stated that GA does global
search in a random fashion. Hence the feed/tooth is highly
fluctuating during the initial generations (up to generation
number 80). After that, the fluctuation of the feed/tooth is
increased and then it converges to optimum values, due to
the population being filled by more fit individuals. The
fluctuation of cutting speed is greater up to the 10th
generation and then it converges to optimum values. The
depth of cut is highly fluctuating up to 40 generations and
then it converges to optimum values. It has been illustrated
in Figs. 5, 6 and 7 that different values are chosen in a
random manner from the specified solution space for
evaluation and this process continues until the solution is
converged. Figure 8 shows the variation of machining time
with number of generations. For the first 25 generations the
fluctuation is greater and then it converges to an optimum
value of 0.54 min. The material removal rate fluctuation is

Fig. 3 Experimental set up for

the determination of cutting
force and vibration signal

Accelerometer at the
work piece holder Vice

Computer
FFT Analyzer Milling Tool
(DI-2200) Dynamometer
 651
Fig. 4 Surface roughness tester

Machined work
Pieces

Surface Roughness Tester

40
greater up to 40 generations, then becomes smaller up to 90
Cutting speed in m/minute
35
generations and then converges to a constant value of 30
6.0103 mm3/min as shown in Fig. 9. 25
20
15
6.2 Surface roughness 10

5
Table 4 shows the comparison of GA results and surface 0
roughness values measured with a surface roughness tester 0 25 50 75 100 125 150 175 200
(Mitutoyo) for the optimized cutting conditions. Figure 10 Generations
shows the variation of surface roughness with number of Fig. 6 Variation of cutting speed with number of generations
generations. It is found that the fluctuation is greater up to
30 generations and then it converges to an optimum value 1.8
of 0.71 m. The surface roughness measured was 2.6 m 1.6
which is within the permissible limit of 6 m for milling
Depth of cut in mm

1.4
operations [12]. The difference in surface roughness 1.2
between GA value and measured value is due to the 1
relative motion between tool and work piece and non- 0.8
homogeneity of the material. 0.6
0.4
0.2
6.3 Tool life 0
0 25 50 75 100 125 150 175 200

The minimum expected life for an HSS tool should be 120 Generations
min [13]. Figure 11 shows the variation of tool life with Fig. 7 Variation of depth of cut with number of generations
number of generations. It is found that the fluctuation of
2.5
Machining Time in minutes

0.35
2.0
Feed Rate in mm/tooth

0.3
0.25 1.5
0.2
1.0
0.15
0.1 0.5

0.05 0.0
0 0 25 50 75 100 125 150 175 200
0 25 50 75 100 125 150 175 200 Generations
Generations
Fig. 8 Variation of machining time with number of generations
Fig. 5 Variation of feed/tooth with number of generations
652
Material removal rate (mm 3/minute) 9000 45000
8000 40000

Tool Life in minutes

7000 35000

6000 30000
25000
5000
20000
4000
15000
3000
10000
2000
5000
1000
0
0
50 100 150 200
0 25 50 75 100 125 150 175 200
Generations
Generations
Fig. 11 Variation of tool life with number of generations
Fig. 9 Variation of material removal rate with number of
generations
x and y directions with number of generations. It is found
Surface Roughness in micron metre

0.8 that the fluctuation is greater up to 40 generations and then

0.7
it converges to an optimum value of 283.62 N and
0.6
457.96 N in the x and y directions, respectively, which is
0.5
below the permissible limit of 500. The cutting force is
0.4
measured with the help of a milling tool dynamometer for
0.3
the optimized cutting parameters as shown in Fig. 3.
0.2
0.1
Table 4 shows the comparison of GA results and measured
0
cutting forces for optimized cutting parameters in the x and
0 25 50 75 100 125 150 175 200 y direction for machining of mild steel material. The good
Generations agreement between the GA results and measured cutting
Fig. 10 Variation of surface roughness with number of generations forces clearly demonstrates the accuracy and effectiveness
of the model presented and program developed.

tool life is greater up to 100 generations, that is above

20,000 min, and then it decreases and converges to an 6.5 Amplitude of vibration (frequency spectrum
optimum value of 16,195 min for the optimized param- analysis)
eters, which is well above the minimum expected tool life
of 120 min. During the optimization process using GA the The maximum limiting depth of cut for stable cutting is
machining parameters, cutting speed and feed/tooth are 1.38 mm for mild steel work piece material and stiffness of
increased in order to minimize the objective function the system but the optimized depth of cut is only 0.92, so it
(machining time). Due to the increase in the machining is under a stable condition. It is also verified experimentally
parameters, tool life decreases as shown in Fig. 11 because
of an increase in tool wear. Tool life is considered as a
Cutting force in X direction in N

400
constraint in this optimization problem and the obtained 350
tool life is well within the boundaries. The optimized
300
parameters obtained from GA will allow the operator to use
250
the tool for a long period of time while maintaining a
200
constant material removal rate as well as stability.
150

100

6.4 Cutting forces 50

0
The cutting parameters are optimized taking a maximum 0 25 50 75 100 125 150 175 200

cutting force of 500 N [14] as the main constraint while Generations

maintaining that wear occurrs as minimum as possible. Fig. 12 Variation of cutting force in x direction with number of
Figures 12 and 13 show the variation of cutting force in the generations

Table 4 Comparison of GA results and experimental values for the optimized cutting parameters
Sl Cutting Feed, Depth of Machining Tool life in GA results Measured values
No speed, m/ mm/ cut, mm time t, minute minutes Roughness Cutting Cutting Roughness Cutting Cutting
min tooth m force Fx, N force Fy, N m force Fx, N force Fy, N

01 38.71 0.30 0.92 0.54 16,195 0.71 283.62 457.96 2.60 290 465

700
Cutting force in Y direction in N
600
500
400
300
200
100
0 recommendations. An optimization technique using GA
0 25 50 75 100
Generations
Fig. 13 Variation of cutting force in y direction with number of
generations
by measuring the amplitude of vibration. A highly sensitive
fast Fourier transform FFT (DI-2200) analyzer is used to
measure vibration level for the optimized cutting param-
eters. The vibration signal picked up at the work piece
holder is shown in Fig. 14 in terms of frequency spectrum.
It is found that the maximum displacement occurring for
the optimized cutting parameter is 1.66 m at 1,280 Hz
which is within the permissible limit of 2 m [15].
6.6 Surface plots
Surface plots have been drawn using Matlab for the
convenience of selecting the best combinations of cutting
parameters. The tool life variation for different combina-
tions of cutting parameters are shown in Fig. 15ac. A low
value of combination provides the highest tool life. The
material removal rate for the combination of work piece
feed and depth of cut is shown in Fig. 15d. The com-
bination of high value of work piece feed and the depth of
cut provide the highest material removal rate. The variation
of machining time for feed/tooth and cutting speed is
shown in Fig. 15e. The combination of high value of
Fig. 14 Frequency spectrum
signal for the optimized cutting
parameters
653
feed/tooth and the cutting speed provide the lowest
machining time.
7 Conclusions
The work described in this paper has made a significant
improvement in machining efficiency over the handbook
125 150 175 200
has been used to machine mild steel work piece under
optimal parameters of feed, cutting speed and depth of cut
for a constant material removal rate in an end-milling
operation. The objective function is minimization of
machining time with constraints like surface roughness,
cutting force, tool life and amplitude of vibration. The
surface roughness of the machined surface for the op-
timized parameters is 2.6 m which is within the
permissible limit of 6.3 m [12]. In this work, the cutting
force has been maintained below 500 N to keep the tool
wear to a minimum for a constant material removal rate.
The good agreement between the GA cutting forces and the
measured cutting forces clearly demonstrates the accuracy
and effectiveness of the model presented and the program
developed. The tool life for the optimized cutting
parameters using GA is 16,195 min which is much more
than the minimum expected tool life of 120 min. The
parameters optimized using GA will allow the operator to
use the tool for a long period in order to maintain a constant
material removal rate as well as stability. The spectrum
analysis from the output of FFT shows the amplitude of
1.66 m at 1,280 Hz for the optimized parameters which
clearly indicates the stability of the cutting process which is
within the permissible limit of 2 m. This helps in
improving surface finish and material removal rate. The
surface plot drawn using Matlab shows the variation of tool
life with the variation of cutting parameters. It helps in
selecting suitable cutting parameters in order to maintain
654

Fig. 15 Variation of machining parameters in end-milling opera- life with feed/tooth and depth of cut. d Variation of material
tions. a Variation of tool life with cutting speed and feed. b Variation removal rate with workpiece feed and depth of cut. e Variation of
of tool life with cutting speed and depth of cut. c Variation of tool machining time with cutting speed and feed/tooth

the tool life. With the GA-based optimization system
developed in this work, it would be possible to increase
machining efficiency by using optimal cutting parameters.
Optimum machining parameters resulting from this work
are intended for use by conventional milling machines.
However, they can also be used by CNC milling machines.
Application of the GA approach to obtain optimal
machining conditions will be quite useful at the computer
aided process planning (CAPP) stages in the production of
high quality goods with tight tolerances by a variety of
machining operations, and in adaptive control of automated
machine tools.
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