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Procedia CIRP 55 (2016) 140 145

5th CIRP Global Web Conference Research and Innovation for Future Production

"Intelligent optimization for sculptured surface CNC tool-paths"

N.A.Fountasa, C.I.Stergioub, V.D.Majstorovi c, N.M.Vaxevanidisa*
a

Laboratory of Manufacturing Processes and Machine Tools (LMProMaT), Dept. of Mechanical Engineering Educators, School of Pedagogical &
Technological Education (ASPETE), N. Heraklion,GR 14121 Athens, Greece
b
Dept. of Mechanical Engineering, Piraeus University of Applied Sciences, Egaleo, GR 122 44, Greece
c
Faculty of Mechanical Engineering, University of Belgrade, Kraljice Marije 16, 11120 Belgrade, Serbia

* Corresponding author. Tel.: +30-210-2896841 ; E-mail address: vaxev@aspete.gr

Abstract
This paper suggests the application of genetic algorithms for the intelligent generation of optimum sculptured surface CNC machining toolpaths. Two robust full quadratic mathematical models are developed relating the physical relation among machining surface deviation and
resulting cutting time; quality objectives which are treated as conflicting ones. The independent variables are the tool inclination angles -lead
and tilt- in the case of 5-axis machining and step-over engagement among subsequent XY passes; using a toroidal cutter. A Box-Behnken
response surface design was established to prepare and conduct simulation experiments in a cutting-edge manufacturing software using a
benchmark multivariable sculptured surface and a special multi-axis tool-path strategy. The genetic algorithm utilizes both models expressed as
a common Pareto-based fitness function so that multi-objective optimization is achieved, yet; arriving at one optimum solution to ease the
efforts of end-users and numerical control programmers. The methodology is validated by utilizing the genetic algorithm's recommendations
for the settings of the machining parameters and the optimum tool-path simulation is performed to verify the operation.
2016
2017The
TheAuthors.
Authors.
Published
by Elsevier
B.V.is an open access article under the CC BY-NC-ND license

Published
by Elsevier
B.V. This
Peer-review under responsibility of the scientific committee of the 5th CIRP Global Web Conference Research and Innovation for Future
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Production.under responsibility of the scientific committee of the 5th CIRP Global Web Conference Research and Innovation for Future Production
Peer-review
Keywords: "scultpured surfaces; CNC machining; artificial intelligence; genetic algorithms"

1. Introduction
Commercially available tool-paths found in existing
manufacturing modeling environments are computed by endusers considering a number of constraints such as cutting tool
type/material; raw material properties and machine tool
specifications; as well as the applicable range for machining
parameters such as axial/radial cutting engagement; tool
inclination angles -in the case of 5-axis machining-; maximum
tool-path discretization step and others. Such parameters are
still conservatively determined; laying heavily in experience
or trial-and-error simulation scenarios to come up with the
most convenient result for actual implementation. Should the
requirements for high accuracy; quality and productivity rates
are taken into account, a need for intelligent optimization

methods for sculptured surface machining tool-paths is

imposed.
Sculptured surface machining spans several research
directions aiming at providing tool-paths for high- precision
machining whilst simultaneously maintaining high
productivity rates. In the past few years a noticeable number
of researchers have focused on creating new tool-path
generation approaches for 3- and 5-axis surface machining [16] capable of operating under a constant interpolation error [79] or maintaining equal scallops [10-13]. Even though such
tool-paths come up with highly sophisticated features for
seamless integration and production facilitation, no significant
aid for machining parameter specifications is provided
whereas their operability is away from being optimum given
their manual selection- even if in most cases is quite
straightforward- and settings.

2212-8271 2016 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of the 5th CIRP Global Web Conference Research and Innovation for Future Production
doi:10.1016/j.procir.2016.08.033

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N.A. Fountas et al. / Procedia CIRP 55 (2016) 140 145

Currently modern soft computing and artificial intelligence

tools are employed to formulate efficient optimization
modules to address complex sculptured surface milling
problems and others found in allied engineering applications.
Li et al. [14] suggested a back-propagation neural network to
optimize a multi-objective optimization problem involving the
cutting conditions. To deal with the problem of generating
poor surface roughness when it comes to tool-path planning
for flank surface milling; Chu et al. [15] developed a splineconstrained tool-path optimization module. In their work, the
coefficients of the spline's equations are determined by
applying a particle swarm optimization scheme. Hsieh and
Chu [16] also addressed 5-axis flank milling problems and a
particle swarm optimization algorithm was implemented to
produce the cutter locations so that the machining error is
reduced. Other research efforts have also presented results
concerning sculptured surface machining optimization
problems using particle swarm optimization (PSO) technique
[17-19]. Other artificial intelligence approaches that have
already been implemented to address complex machining
optimization problems include artificial immune systems [20]
and hybrid modules incorporating more than one intelligent
functions [21]. Despite the vast development of soft
computing techniques to facilitate optimization tasks genetic
algorithms remain the most efficient tools for optimizing
problems. Their robust stand-alone functionality has already
drawn the attention of numerous researchers worldwide and
their implementation spans research contributions which
differentiate their research methodology whilst addressing
more or less the same objectives; ending up with remarkable
results for practical solutions [22-31].
This study employs a genetic algorithm to minimize the
objectives of surface deviation and tool-path time. The
optimum solution among the rest ones is found in the
corresponding Pareto front via the repetitive evaluation of a
common function incorporating two robust multiple full
quadratic regression-based mathematical models; one to
predict surface deviation and one for tool-path time. The work
differs from others related, mainly in the context of
experimenting and finally obtaining meaningful results from
modern manufacturing systems (i.e. CAM software) for
optimization systems development and integration. Note that
such an approach is practically the safest way to conduct
experiments whilst the cost of actual resources and materials
is dramatically reduced, yet; providing trustworthy and
applicable results.

Nomenclature
ANOVA
CAM
GA
ObjFun
SDev
TlpTime

Analysis of Variance
Computer-aided Manufacturing
Genetic algorithm
Objective function
Surface deviation
Tool-path time

2. Research framework for tool-path optimization

The sculptured surface tool-path optimization problem was
determined by examining the responses of surface deviation
and tool-path time against the set of the independent
variables; step-over, lead angle and tilt angle; under a BoxBehnken response surface design. 15 experiments were
performed in SIEMENS NX10 machining environment
where a 40x40 mm benchmark sculptured surface (Eq. 1)
[27]; was utilized to perform tool-path simulations and obtain
the outputs for the responses.

f ( x, y) 3(cos( yS / 20)sin( xS / 20)  3

(1)

Surface deviation represents the machining error that exists

between the theoretical surface and the surface produced after
subtracting the swept volume owing to the cutting tool's
envelope towards its feed interpolation. The resulting
machining error is thus the combined effect of chord error and
scallop height. The former refers to the deviation yielded
towards the longitudinal direction whereas the latter refers to
the transversal step.
The cutting strategy employed was a zig-zag trajectory
under dual-axis on drive contour with intermediate XY tool
passes to eliminate the scallops among the subsequent radial
cutting steps and fit the local curvatures of the studied surface
by simultaneously varying primary (lead angle) and secondary
(tilt angle) axes. When it comes to multi-axis surface
machining toroidal cutters are usually implemented owing to
their efficiency and high-performance against ball-end mills
or flat-end mills [32-34]. Given the basic dimensions of the
test surface mentioned above, a 6mm toroidal end-mill with
1mm corner radius was determined whilst the cutting
tolerance was set to 0.01mm. The test benchmark surface was
divided to 20 zones towards X direction and 20 zones towards
Y direction, thus; ending up with a set of 400; equally spaced
discrete points which were measured using software tools
found in the same environment. For each of the 15
experimental runs; the surface deviation between the
theoretical and the simulated surface was considered to be the
mean value of the 400 measurements conducted for each of
the 15 simulated CAM model outputs.
Two full quadratic relationships involving the independent
variables (step-over; lead angle and tilt angle) and the
responses (surface deviation and tool-path time) were finally
generated; the quality of which was further assessed through
analysis of variance (ANOVA) and prediction experiments.
Based on these models the objective function for a genetic
algorithm was developed, so that the output would depict the
distance from the Pareto front origin (0,0) to the computed
point given its coordinates determined by the values for
surface deviation and normalized tool-path time.
Normalization was performed owing to the difference
between the responses' magnitudes which could involuntarily
affect the final outcome via their inherent bias. The final
objective function was passed onto the Mathworks
MATLAB's genetic algorithm routines for further evaluations
until convergence.

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3. Results and discussion

3.1. Design of machining simulation experiments
Response surface Methodology (RSM) can provide
intermediate observations given a finite design space against
Taguchi robust design with the corresponding orthogonal
arrays. In addition, full quadratic model generation is
facilitated in RSM whilst fewer experiments are required for
the same number of parameters and levels. Table 1 illustrates
the Box-Behnken response surface design using the three
aforementioned tool-path parameters along with their lowest;
middle and the highest levels.
Table 1. Tool-path parameters and corresponding levels.
Tool-path parameters/coded
levels
Step-over (no. XY passes)

Results obtained were analyzed using MINITAB 17

statistical processing package. First observations led to the
expected outcome of dealing with a highly non-parametric
fitting problem that leaves no room for speculating any kind
of parametric relationship among the parameters involved.
Table 2 presents the experimental results for surface deviation
and tool-path time considering the values for the independent
variables.
Table 2. Parameter values and experimental results.
XY-pass

Lead (deg)

Tilt (deg)

S.Dev. (mm)

TlpTime (min)

25

0.5

1.25

0.172445

1.916

75

0.5

1.25

0.113876

7.733

25

1.25

0.138220

1.8

75

1.25

0.127715

8.083

-1

25

2.5

0.130572

25

50

75

75

2.5

0.124786

8.033

(0.53mm)

25

2.5

2.75

0.200745

0.3003

Lead angle (deg)

(1.6mm)
0.5

(0.8mm)
2.5

75

2.5

2.75

0.149114

0.7867

Tilt angle (deg)

1.25

2.75

50

0.5

0.132551

0.365

50

0.120159

0.5683

50

0.5

2.75

0.123305

0.5383

50

2.75

0.172660

0.5467

50

2.5

1.25

0.118081

0.57

50

2.5

1.25

0.118081

0.57

50

2.5

1.25

0.118081

0.57

The 400 measurements conducted to each of the 15

virtually machined models, were normal to surface whilst they
were determined by examining both X and Y directions.
Mean resulting deviation was kept to represent the total
machining error. Fig.1 depicts the sculptured model tested and
the tool-path applied.

Several regression models such as general exponential

were tested for their quality in predicting the responses. Full
quadratic models finally created were found the most
appropriate ones since their corresponding statistical analysis
revealed that the models could capture both the trend and the
noise of the experimental observations. The models generated
to fit the experimental data for surface deviation and tool-path
time are given in Eq.2 for the surface deviation SDev and Eq.
3 for the tool-path time TlpTime
SDev = 0.2547 - 0.00410 * x(1) - 0.00158 * x(2) 0.0094 * x(3) + 0.000033 * x(1)^2 - 0.00029 * x(2)^2 +
0.00597 * x(3)^2 +0.000208 * x(1) * x(2) -0.000326 *
(2)
x(1) * x(3) +0.00729 * x(2) * x(3)
TlpTime = -0.237 + 0.01370 * x(1) + 0.0909 * x(2) +
0.0659 * x(3) -0.000031 * x(1)^2 - 0.01312 * x(2)^2 0.0025 * x(3)^2 + 0.000259 * x(1) * x(2) - 0.000193 *
(3)
x(3) - 0.01416 * x(2) * x(3)

where, x(1) is the parameter for step-over; x(2) for the

parameter of lead angle; and x(3) the parameter for tilt angle.
Fig.2 and Fig.3 illustrate the envelopes concerning the
relation among the experimental and the predicted data for the
surface deviation and the tool-path time respectively. Both
quadratic models shown good correlation among experimental
and predicted data hence they deemed adequate to be used for
the formulation of the fitness function.
Fig. 1. (a) Experimental sculptured part; (b) 5-axis tool-path studied.

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N.A. Fountas et al. / Procedia CIRP 55 (2016) 140 145

vectorized attribute was given holding three elements whilst

ObjFun parameter was specified to reflect the two
objectives. ObjFun measures the distance of solution points
existing in a Pareto front; from the latter's origin. By taking
into account this assumption, the final objective function was
formulated in the expression presented in Eq.4.

ObjFun

Fig. 2. Comparison between experimental and predicted surface deviation

envelopes.

SDev 2  TlpTime2

(4)

Parameters for the intelligent operators were MATLAB's

default values. 15 evaluations were conducted to validate the
optimum parameter set whilst corresponded convergence
diagrams were examined to check the final fitness value. The
algorithm exhibited in general, good repeatability. The fitness
function values for these validation runs as well as the
optimum final points for the independent variables obtained;
are tabulated in Table 3. Fig. 4 illustrates the convergence
diagram of the lowest "optimum" final point.
Table 3. Genetic algorithm validation evaluations and optimum final points.

Fig. 3. Comparison between experimental and predicted tool-path time

envelopes.

3.2. Intelligent tool-path optimization using a genetic

algorithm
A constrained multi-objective optimization problem with
three inputs and two objectives is handled by the multiobjective genetic algorithm solver of Mathworks MATLAB.
The three inputs are set as a vector v = [v(1), v(2), v(n)] whilst
the two objectives are represented as f = [f(1), f(2)]. The
inputs are bound to different constraint ranges owing to their
heterogeneous nature. Hence; step-over expressed in the form
of number of XY passes was within [25-75]; lead angle for
the primary rotational axis within [0.5-5] and tilt angle for the
secondary rotational axis; within [0-2.75]. This decision
making was done for the hypothetical consideration of
physical constraints in terms of tool axis variation limits as
well as the examination of the designed parameter range.
Special emphasis was given to the precedence constraints in
terms of minimum and maximum input parameters' ranges
ensuring thus that results would not occur out of the vicinity
that the aforementioned applicable ranges impose. Further
settings involved the maximum generations number which
was set to 50. Population size was set to 50 as well; meaning
that both parents and offspring would represent 50 candidate
solutions in each iteration. To achieve multi-objective
optimization handling two objectives and three variables, a

GA run

ObjFun

x(1)

x(2)

x(3)

0.18166822

36.511

4.999

0.001

0.18211309

36.533

4.998

0.003

0.18184262

36.529

4.998

0.001

0.18237243

36.753

4.994

0.001

0.18176456

36.52

4.999

0.001

0.18249395

36.557

4.996

0.004

0.18201604

36.595

4.999

0.003

0.18167981

36.519

4.999

0.001

0.18202008

36.7

4.999

0.003

10

0.18181336

36.526

4.999

0.002

11

0.18179491

36.522

4.999

0.001

12

0.18188469

36.785

4.999

0.002

13

0.18175666

36.501

4.999

0.001

14

0.18165303

36.517

4.999

0.000

15

0.18161174

36.517

5.000

0.000

Fig. 4. Convergence diagram for the best validation evaluation.

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N.A. Fountas et al. / Procedia CIRP 55 (2016) 140 145

Results from final points show that the number of passes

should be as low as possible to facilitate machining time, yet;
without violating surface finish the quality of which is
expressed here via surface deviation of the virtually
manufactured models with reference to the theoretically
designed one. For the 6 mm toroidal tool employed the
number of passes equal to the optimal value of 36.517 (GA
run 5; see table 2) corresponds to 1.095 mm (18.25% of the
6 mm cutting diameter). Note that the specific cutter - and
every cutter - starts to produce noticeable scallop when stepover engagement exceeds 50% of the cutting diameter. The
value of 18.25% referring to the cutting diameter percentage
is large enough to formulate a quite productive tool-path with
the simultaneous optimization of scallop. Optimum lead angle
is given equal to 5 deg and tilt angle 0 deg. Given the tool's
geometry and small diameter, very small inclination towards
the feed direction is necessary to avoid tool tip contact with
the surface as well as fitting the local curvatures.
The recommended optimum machining parameters by the
genetic algorithm were applied to the same tool-path strategy
to simulate the result and collect validation data. Virtual
normal-to-surface measurements were evaluated exactly at the
same locations and the mean value was computed to represent
the error. Spindle speed was set to 8000 rpm and feed velocity
was set to 250 mm/min. The optimum tool-path needed 17 sec
(0.28 min) to simulate the result which was lower that the
lowest simulation time found in the 15 response surface
experiments (0.3003 min). Hence; simulation time reduction
considering the best result from the response surface
experiments, was 6.76%. Mean surface deviation (mean
value) was computed equal to 0.112367143 mm against the
lowest experimental mean value which was 0.113876 mm.
The percentage gain is 1.325%. The latter percentage seems to
hold no observable merit, yet; should surface finish
requirements usually imposed in physical operations are taken
into account for sculptured surfaces, this result could be quite
significant. In addition, assessment concerning the final
outcome is referred to the common objective of surface
deviation and tool-path time under equal importance. Thus;
the true performance gain should be given in terms of the
multi-objective output that the determined fitness equation
predicts. Table 4 gives the values of the two objectives as they
were presented above (Table 2); accompanied by the common
objective function value in terms of the Pareto multi-objective
optimum point distance depiction from the origin.

TlpTime (min)

0.172445

1.916

0.113876

7.733

0.138220

1.8

0.127715

8.083

0.130572

0.124786

8.033

0.200745

0.3003

0.149114

0.7867

0.132551

0.365

0.5683

0.602680424

0.123305

0.5383

0.617836673

0.172660

0.5467

0.862751396

0.118081

0.57

0.592425891

0.118081

0.57

0.592425891

0.118081

0.57

0.592425891

It can be seen from the results of table 4, that the lowest

predicted value for the common objective studied here, is
0.592425891 (last experimental objective function outputs).
Comparing the results obtained from the full quadratic
prediction equation implementation and the same equation if
handled by the genetic algorithm as the fitness; the optimum
algorithm value of 0.18161174 gives an overall gain equal to
30.65%. Further observations during the validation simulation
include reduced non-cutting motions; less joining distances
referring to tool-path passes and smoother resulting surface.
4. Conclusions
The methodology presented in this work constitutes an
efficient optimization framework in the special case of
sculptured surface CNC tool-path optimization. Its efficiency
lies heavily on the stochastic exploration of the problem's
regions via the genetic algorithm; the quality of which has
extensively been mentioned by several researchers working
on the same problem or similar ones found in common
manufacturing optimization tasks [35, 36]. Even if the
problem mentioned is a well-established research field, no
significant efforts have yet been made to provide optimization
infrastructure using machining modeling environment and
intelligent systems. From production engineering perspectives
the methodology dramatically reduces evaluation costs since
no physical experimentation is required and main work is
conducted using latest generation tool-path planning software.
Table 5 gives the overall GA results against experimental and
predicted outputs.
Table 5. Final results for objective function and quantitative gains.
ObjF (Exp)

ObjF (Pred)

ObjF (GA)

0.891129885

0.91352

0.18166822

20.39%

19.89%

1.112234335

1.02512

0.18211309

16.37%

17.77%

0.723651426

0.4671875

0.18184262

25.13%

38.92%

1.185224441

0.8193125

0.18237243

15.39%

22.26%

0.748879344

0.5675

0.18176456

24.27%

32.03%

ObjFun = Sqrt (S.Dev2+TlpTime2)

1.172207827

1.104125

0.18249395

15.57%

16.53%

0.891129885

1.000689899

0.91015

0.18201604

18.19%

20.00%

1.112234335

0.749152234

0.7469

0.18167981

24.25%

24.32%

0.723651426

0.661837687

0.7415075

0.18202008

27.50%

24.55%

1.185224441

0.602680424

0.272

0.18181336

30.17%

66.84%

0.748879344

0.617836673

0.59397

0.18179491

29.42%

30.61%

1.172207827

0.862751396

0.440025

0.18188469

21.08%

41.34%

1.000689899

0.592425891

0.506125

0.18175666

30.68%

35.91%

0.749152234

0.592425891

0.506125

0.18165303

30.66%

35.89%

0.661837687

0.592425891

0.506125

0.18161174

30.66%

35.88%

Table 4. Experimental results for objectives and predicted fitness.

S.Dev. (mm)

0.120159

GA vs Exp

GA vs Pred

N.A. Fountas et al. / Procedia CIRP 55 (2016) 140 145

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