INTERNATIONAL JOURNAL Of ACADEMIC RESEARCH Vol. 3. No. 3.

May, 2011, II Part

REVIEW ON OPTIMIZATION OF MACHINING OPERATION

1 2
C. Dhavamani , T. Alwarsamy
1
Asst.Prof , Department of Mechanical Engg, Mahendra Engineering College, Namakkal-637503
2
Professor of Mech Engg Liaison Officer, DOTE, Chennai-25, (INDIA)

ABSTRACT

In this paper an attempt is made to review the literature on optimizing the machining parameters in drilling
processes. Various conventional techniques employed for machining optimization include geometric programming
geometric plus linear programming, Non-Linear Programming, goal programming, sequential unconstrained
minimization technique and dynamic programming etc. The latest techniques for optimization include fuzzy logic,
scatter search technique, ant colony technique, genetic algorithm, Taguchi technique and response surface
methodology are being applied successfully in industrial applications for optimal selection of process variables in
the area of machining. Taguchi methods is latest design techniques widely used in industries for making the
product/process insensitive to any uncontrollable factors such as environmental variables

Key words: machining operation, drilling process, programming, fuzzy logic, Taguchi methods

1. INTRODUCTION

It has long been recognized that conditions during cutting, such as feed rate, cutting speed and diameter of
cut, should be selected to optimize the economics of machining operations. Drilling of composite material substan-
tially different from metallic materials due to its mechanical properties. The drilling of this material may generate
delamination of drilled holes on work piece. The objective of this research is to study the effect of cutting speed,
feed, diameter of cut, machining time on metal removal rate, specific energy, surface roughness, volume fraction
and flank wear.
Taylor showed that an optimum or economic cutting speed exists which could maximize material removal rate.
Considerable efforts are still in progress on the use of hand book based conservative cutting conditions and cutting tool
selection at the process planning level. The need for selecting and implementing optimal machining conditions and most
suitable cutting tool has been felt over the last few decades. Despite Taylor’s early work on establishing optimum cutting
speeds in machining, progress has been slow since all the process parameters need to be optimized. Furthermore, for
realistic solutions, the many constraints met in practice, such as low machine tool power, torque, force limits and
component surface roughness must be overcome.

2. REVIEW OF CONVENTIONAL OPTIMIZATION TECHNIQUES

Traditionally, the selection of cutting conditions for metal cutting is left to the machine operator. In such
cases, the experience of the operator plays a major role, but even for a skilled operator it is very difficult to attain
the optimum values each time. Machining parameters in metal drilling are cutting speed, feed rate and dia of cut.
The setting of these parameters determines the quality characteristics of turned parts. Following the pioneering
work of Taylor (1907) and his famous tool life equation, different analytical and experimental approaches for the
optimization of machining parameters have been investigated. Gilbert (1950) studied the optimization of machining
parameters in turning with respect to maximum production rate and minimum production cost as criteria. Armarego
& Brown (1969) investigated unconstrained machine-parameter optimization using differential calculus.Brewer &
Rueda (1963) carried out simplified optimum analysis for non-ferrous materials. For cast iron (CI) and steels, they
employed the criterion of reducing the machining cost to a minimum. A number of nomograms were worked out to
facilitate the practical determination of the most economic machining conditions. They pointed out that the more
difficult- to-machine materials have a restricted range of parameters over which machining can be carried out and
thus any attempt at optimizing their costs is artificial. Brewer (1966) suggested the use of Lagrangian multipliers for
optimization of the constrained problem of unit cost, with cutting power as the main constraint. Walvekar & Lambert
(1970) discussed the use of geometric programming to selection of machining variables. They optimized cutting
speed and feed rate to yield minimum production cost. Petropoulos (1973) investigated optimal selection of
machining rate variables, viz. cutting speed and feed rate, by geometric programming. Sundaram (1978) applied a
goal-programming technique in metal cutting for selecting levels of machining parameters in a fine operation on
AISI 4140 steel using cemented tungsten carbide tools. Ermer & Kromodiharajo (1981) developed a multi-step
mathematical Optimization of machining techniques 701 model to solve a constrained multi-pass machining
problem. They concluded that in some cases with certain constant total depths of cut, multi-pass machining was
more economical than single-pass machining, if depth of cut for each pass was properly allocated. They used high
speed steel (HSS) cutting tools to machine carbon steel. Hinduja et al (1985) described a procedure to calculate
the optimum cutting conditions for machining operations with minimum cost or maximum production rate as the
objective function. For a given combination of tool and work material, the search for the optimum was confined to a
feed rate versus depth-of-cut plane defined by the chip-breaking constraint. Some of the other constraints
considered include power available, work holding, surface finish and dimensional accuracy. Tsai (1986) studied the
relationship between the multi-pass machining and single-pass machining. He presented the concept of a break-
even point, i.e. there is always a point, a certain value of depth of cut, at which single-pass and double-pass

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machining are equally effective. When the depth of cut drops below the break-even point, the single-pass is more
economical than the double-pass, and when the depth of cut rises above this break-even point, double-pass is
better. Carbide tools are used to machine the carbon steel work material. Gopalakrishnan & Khayyal (1991)
described the design and development of an analytical tool for the selection of machine parameters in drilling.
Geometric programming was used as the basic methodology to determine values for feed rate and cutting speed
that minimize the total cost of machining SAE 1045 steel with cemented carbide tools of ISO P-10 grade. Surface
finish and machine power were taken as the constraints while optimizing cutting speed and feed rate for a given
depth of cut. Agapiou (1992) formulated single-pass and multi-pass machining operations. Production cost and
total time were taken as objectives and a weighting factor was assigned to prioritize the two objectives in the
objective function. He optimized the number of passes, depth of cut, cutting speed and feed rate in his model,
through a multi-stage solution process called dynamic programming. Several physical constraints were considered
and applied in his model. In his solution methodology, every cutting pass is independent of the previous pass;
hence the optimality for each pass is not reached simultaneously. Prasad et al (1997) reported the development of
an optimization module for determining process parameters for operations as part of a PC-based generative CAPP
system. The work piece materials considered in their study include steels, cast iron, aluminium, copper and brass.
HSS and carbide tool materials are considered in this study. The minimization of production time is taken as the
basis for formulating the objective function. The constraints considered in this work include power, surface finish,
tolerance, and work piece rigidity, range of cutting speed, maximum and minimum depths of cut and total depth of
cut. Improved mathematical models are formulated by modifying the tolerance and work piece rigidity constraints
for multi-pass turning operations.

3. REVIEW ON LATEST TECHNIQUES

The latest techniques for optimization include fuzzy logic, scatter search technique, ant colony technique,
genetic algorithm, Taguchi technique and response surface methodology.

3.1 Fuzzy logic

Fuzzy logic has great capability to capture human commonsense reasoning, decision-making and other
aspects of human cognition. Kosko (1997) shows that it overcomes the limitations of classic logical systems, which
impose inherent restrictions on representation of imprecise concepts. Vagueness in the coefficients and constraints
may be naturally modelled by fuzzy logic. Modelling by fuzzy logic opens up a new way to optimize cutting
conditions and also tool selection.

3.1a Methodology: Klir & Yuan (1998) fuzzy logic involves a fuzzy interference engine and a fuzzification-
defuzzification module. Fuzzification expresses the input variables in the form of fuzzy membership values based
on various membership functions. Governing rules in linguistic form, such as if cutting force is high and machining
time is high, then tool wear is high, are formulated on the basis of experimental observations. Based on each rule,
inference can be drawn on output grade and membership value. Inferences obtained from various rules are
combined to arrive at a final decision. The membership values thus obtained are defuzzified using various
techniques to obtain true value.

3.2 Genetic algorithm (GA)

These are the algorithms based on mechanics of natural selection and natural genetics, which are more
robust and more likely to locate global optimum. It is because of this feature that GA goes through solution space
starting from a group of points and not from a single point. The cutting conditions are encoded as genes by binary
encoding to apply GA in optimization of machining parameters. A set of genes is combined together to form
chromosomes, used to perform the basic mechanisms in GA, such as crossover and mutation. Crossover is the
operation to exchange some part of two chromosomes to generate new offspring, which is important when
exploring the whole search space rapidly. Mutation is applied after crossover to provide a small randomness to the
new chromosomes. To evaluate each individual or chromosome, the encoded cutting conditions are decoded from
the chromosomes and are used to predict machining performance measures. Fitness or objective function is a
function needed in the optimization process and selection of next generation in genetic algorithm. Optimum results
of cutting conditions are obtained by comparison of values of objective functions among all individuals after a
number of iterations. Besides weighting factors and constraints, suitable parameters of GA are required to operate
efficiently. GA optimization methodology is based on machining performance predictions models developed from a
comprehensive system of theoretical analysis, experimental database and numerical methods. The GA parameters
along with relevant objective functions and set of machining performance constraints are imposed on GA
optimization methodology to provide optimum cutting conditions.

3.2a Implementation of GA: First of all, the variables are encoded as n-bit binary numbers assigned in a
row as chromosome strings. To implement constraints in GA, penalties are given to individuals out of constraint. If
an individual is out of constraint, its fitness will be assigned as zero. Because individuals are selected to mate
according to fitness value, zero fitness individuals will not become parents. Thus most individuals in the next
generation are ensured in feasible regions bounded by constraints. The GA is initialized by randomly selecting
individuals in the full range of variables. Individuals are selected to be parents of the next generation according to
their fitness value. The larger the fitness value, the greater their possibility of being selected as parents.Wang &

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Jawahir (2004) have used this technique for optimization of milling machine parameters. Kuo & Yen (2002) have
used a genetic algorithm based parameter tuning algorithm for multidimensional motion control of a computer
numerical control machine tool.

3.3 Scatter search technique (SS)

This technique originates from strategies for combining decision rules and surrogate constraints. SS is
completely generalized and problem-independent since it has no restrictive assumptions about objective function,
parameter set and constraint set. It can be easily modified to optimize machining operation under various economic
criteria and numerous practical constraints. It can obtain near-optimal solutions within reasonable execution time
on PC. Potentially, it can be extended as an on-line quality control strategy for optimizing machining parameters
based on signals from sensors. Chen & Chen (2003) have done extensive work on this technique.

3.3a Methodology:
First of all, machining models are required to determine the optimum machining parameters including cutting
speed, feed rate and depth of cut, in order to minimizeunit production cost. Unit production cost can be divided into
four basic cost elements:
• Cutting cost by actual cut in time
• Machine idle cost due to loading and unloading operation and idling tool motion cost
• Tool replacement cost
• Tool cost
For the optimization of unit production cost, practical constraints which present the state of machining
processes need to be considered. The constraints imposed during machining operations are:
• Parameter constraint – Ranges of cutting speed, feed rate and depth of cut
• Tool life constraint – Allowable values of flank wear width and crater wear depth
• Operating constraint – Maximum allowable cutting force, power available on machine tool and surface
finish requirement.
An optimization model for multi-pass turning operation can be formulated. The multipass turning model is a
constrained nonlinear programming problem with multiple variables (machining variables). The initial solution for
SS is picked in a randomway. The user- pecified parameters have to be given. The experimentation can be run on
a PC with Pentium800Mhz processor. The computational results validate the advantage of SS in terms of solution
quality and computational requirement.

3.4 Taguchi technique

Genichi Taguchi is a Japanese engineer who has been active in the improvement of Japan’s industrial
products and processes since the late 1940s. He has developed both the philosophy and methodology for process
or product quality improvement that depends heavily on statistical concepts and tools, especially statistically
designed experiments. Many Japanese firms have achieved great success by applying his methods.Wu (1982) has
reported that thousands of engineers have performed tens of thousands of experiments based on his teachings.
Sullivan (1987) reports that Taguchi has received some of Japan’s most prestigious awards for quality
achievement, including the Deming prize. In 1986, Taguchi received the most prestigious prize from the
International Technology Institute – TheWillard F. Rockwell Medal for Excellence in Technology. Taguchi’s major
contribution has involved combining engineering and statistical methods to achieve rapid improvements in cost and
quality by optimizing product design and manufacturing processes. Barker (1990) reported that since 1983, after
Taguchi’s association with the top companies and institutes in USA (AT & T Bell Laboratories, Xerox, Lawrence
Institute of Technology (LIT), Ford Motor Company etc.), his methods have been called a radical approach to
quality, experimental design and engineering. Sullivan (1987) reported that the term “Taguchi methods” (TM) refers
to the parameter design, tolerance design, quality loss function, on-line quality control, design of experiments using
orthogonal arrays, and methodology applied to evaluate measuring systems. Pignatiello (1988) identifies two
separate aspects of the Taguchi methods: the strategy of Taguchi and the tactics of Taguchi. Taguchi tactics refer
to the collection of specific methods and techniques used by Genichi Taguchi, and Taguchi strategy is the
conceptual framework or structure for planning a product or process design experiment. Ryan (1988) and Benton
(1991) reported that Taguchi addresses design and engineering (off-line) as well as manufacturing (on-line) quality.
This fundamentally differentiates TM from statistical process control (SPC), which is purely an on-line quality
control method. Taguchi’s ideas can be distilled into two fundamental concepts:
(a) Quality losses must be defined as deviations from targets, not conformance to arbitrary specifications
(Benton 1991).
(b) Achieving high system-quality levels economically requires quality to be designed into the product.
Quality is designed, not manufactured, into the product (Daetz 1987; Taguchi 1989).
Lin et al (1990) stated that Taguchi methods represent a new philosophy. Quality is measured by the
deviation of a functional characteristic from its target value. Noises (uncontrolled variables) can cause such
deviations resulting in loss of quality. Taguchi methods seek to remove the effect of noises. Taguchi (1989)
described that quality engineering encompasses all stages of product/process development: system design,
parameter design, and tolerance design. Byrne & Taguchi (1987), however, pointed out that the key element for
achieving high quality and low cost is parameter design. Through parameter design, levels of product and process
factors are determined, such that the product’s functional characteristics are optimized and the effect of noise
factors is minimized. Kackar & Shoemaker (1986) observed that parameter design reduces performance variation

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by reducing the influence of the sources of variation rather than by controlling them, it is thus a very cost-effective
technique for improving engineering design.

3.5 Response surface methodology (RSM)

Experimentation and making inferences are the twin features of general scientific methodology. Statistics as
a scientific discipline is mainly designed to achieve these objectives. Planning of experiments is particularly very
useful in deriving clear and accurate conclusions from the experimental observations, on the basis of which
inferences can be made in the best possible manner. The methodology for making inferences has three main
aspects. First, it establishes methods for drawing inferences from observations when these are not exact but
subject to variation, because inferences are not exact but probabilistic in nature. Second, it specifies methods for
collection of data appropriately, so that assumptions for the application of appropriate statistical methods to them
are satisfied. Lastly, techniques for proper interpretation of results are devised. The advantages of design of
experiments as reported by Adler et al (1975) and Johnston (1964) are as follows.
(1) Numbers of trials are reduced.
(2) Optimum values of parameters can be determined.
(3) Assessment of experimental error can be made.
(4) Qualitative estimation of parameters can be made.
(5) Inference regarding the effect of parameters on the characteristics of the process can be made. Cochran
& Cox (1962) quoted Box andWilson as having proposed response surface methodology for the optimization of
experiments. Box & Hunter (1957) have proposed that the scheme based on central composite rotatable design fits
the second-order response surfaces very accurately.

Table 3.1 Summary of recent machining optimization technique:

Techniques Authors Tools used Remarks

Taguchi Gu Tosum & Mehtap Optimum surface roughness was Surface integrity of drilled Al/17% SiC
Muatoglu (2003) determined when the solid carbide drill particulate MMCs. Dry drilling spindle
tools were used on the specimens with speed , feed rates, drills, Point angles of
peakaged condition drill and heat treatment were conducted .
Taguchi Thomas & king (1996) Fracture surfaces were examined Improvement of the Mechanical Properties
Technique optically and in a scanning electron of 2124 Al/SiCp MMC plate by optimization
of the solution treatment
Micro Genetic Ramon Quiza Sadinas, The obtained outcomes were arranged Multi-Objective Optimization of cutting
Algorithm. Pedro Ries, J.Paul in graphical form and analyzed to parameters for drilling Laminate Composite
Posteriori Davim (2006) make the proper decision for different materials by using G.A
approach. process preferences.
Design of Mohan,.Kulkarni, The measured results were collected Optimization of process parameters during
Experiments, Ramachandra (2009) and analyzed with the help of drilling of Glass-fiber Polyester reinforced
ANOVA commercial software package composites using DOE and ANOVA.
MINITAB14 and Taly profile.s Main objective is to optimize the process
parameters to achieve low cutting thrust,
torque and good surface roughness.
Taguchi Guey-Jiuh Tzou, The signal to Noise ratio and Analysis The roundness and flank wear of the
Ding-yeng chen, of variance (ANOVA) are employed to ultrasonically and conventionally machined
Chun-Yao Hsu. study the performance work pieces were measured and compared.
Neural Network Uros Zperl and Franc To reach higher precision of the Optimization of cutting conditions during
cus (2000) predicted results a neural optimization machining by using Neural. The approach
algorithm is developed and presented is suitable for fast determination of optimum
to ensure simple, fast and efficient cutting parameters during machining .
optimization of all parameters.
Design of Criston Reliable chip removal, cutting with low Optimization elements for Deep-hole
Experiments Constantinescu, Mirca forces and high tool life. drilling. Method for entering angle,
cozminca, and irina eccentricity and chip breaking , shoulder
croitoru(2001) dimensions optimization
Genetic J.PauloDavim The concept of the Pareto optimum Optimal drilling of particular metal matrix
Algorithm. C.A.Conceicao Antonia solution is considered in the composites based on experimental and
(2000) optimization procedure. numerical procedures. An evoluation
strategy is adopted to obtain the optimal
solution for cutting speed, feed rate, and
tool life.

Taguchi Basavarajapa Analysis of variance are employed to Some Studies on drilling of hybrid metal
Technique , Chandramohan analyse the drilling characteristics of matrix composites based on Taguchi
ANOVA Paulo Davim (2008) these composites. Techniques.
Taguchi Mohan Analysis of variance (ANOVA) is used Influence of process Parameters on cutting
optimization Ramachandra to study the effect of process force and torque during drilling of Glass-
technology M.Kulkarni (2005) parameters on machining process. Fiber Polyester reinforced composites. The
MINITAB14 package is used , main objective is to find the important
Orthoganal array , Signal to noise ratio factors and combination of factors influence
are employed. the machining process to achieve low
cutting thrust and torque.

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Multiple objective D.kim Analysis of variance (ANOVA) Drilling Process optimization for graphite /
linear program M.Ramulu (2003) bismaleimide -Titanium ally stacks
Taguchi Paulo Davim.Pedro The Analysis of Variance (ANOVA) Machinability study on Polyether ether
Reis, Vitro Lapa, was performed to investigate the Keton (PEEK) reinforced (GF30) for
C.Conceicao Antonia cutting characteristics of PEEK applications in structural component
(2003)
Artificial Neural L.yu, L.Cheng, Yam, An artificial neural network (ANN) is Experimental validation of vibration based
Network. Yan, Jiang (2006) trained using numerically simulated damage detection for static laminated
structural damage index to establish composite shells partially filled with fluid
the mapping relationship between the
structural damage index and damage
status.
Taguchi analysis Tsao, Hocheng (2004) Analysis of Variance (ANOVA) Taguchi analysis of delamination
associated with various drill bits in drilling of
composite materials
Orthogonal Noorul Haq Marimuthu multiple responses based on Multi response optimization of machining
array - Grey and Jeyapaul (2007) orthogonal array with grey relational parameters of drilling Al/SiC metal matrix
relational analysis. Based on the grey relational composite using grey relational analysis in
analysis - grade, optimum levels of parameters the taguchi method
ANOVA have been identified and significant
contribution of parameters is
determined by ANOVA
Taguchi Palanikumar, Fuzzy logic to optimize the machining Optimization of the Machinability of the Al-
Karunamoorthy, parameters for machining of GFRP SiC Metal Matrix Composite Using the
Karthikeyan, and composites. A multi response Dynamic Material Model
Latha. performance index (MRP) was used
for optimization
Taguchi E. Kilickap (2010) ANOVA, analysis of signal-to-noise Optimization of cutting parameters on
ratio delamination based on Taguchi method
during drilling of GFRP composite

Taguchi’s Mustafa Kurt Orthogonal arrays of Taguchi, the Application of Taguchi methods in the
2
experimental Eyup Bagci and signal-to-noise (S/N) ratio, the analysis optimization of cutting parameters for
design method Yusuf Kaynak of variance (ANOVA), and regression surface finish and hole diameter accuracy
(2008) analyses in dry drilling processes

Taguchi’s Gaintonde, Karnik, The fitness function is derived through Tauguchi approach with multiple
optimization Achuytha, & mapping the objective function of the performance characteristics for burr size
technique Siddeswarappa (2006) drill optimization problem. minimization in drilling

Minimum Milon brozek, Rostislav Cutting condition optimizations were Optimization of cutting conditions at drilling.
machining costs choteborsky, Miroslav calculated for the minimum machining
criterian. muller , petr HRABE ( costs criterion using the basic
2007) economic indexes of the workshop
Fuzzy Logic Vimal sam singh , L27 orthoganal array, fuzzy based Modeling and Analysis of thrust force and
Latha and model is developed to predict thrust torque in drilling GFRP composites by
Senthilkumar (2009) force and torque. multi-facet drill using fuzzy logic.
Design of Dong-Woo Kim ANOVA (Analysis of to minimize the thrust
Experiments Myeong-Woo Cho 1, Variance) is carried out forces in the step-feed micro drilling
Tae-Il Seo and Eung- process by application of the DOE (Design
Sug Lee (2008) of Experiment) method.

Response Palanikumar , Analysis of variance is used for Analysis and optimisation of cutting
Surface Shanmugam , Paulo checking the validity of the model parameters for surface roughness in
Methodology Davim (2010) machining Al/SiC particulate composites by
PCD tool

Taguchi Method Kishore,Tiwari.& Singh An attempt to investigate Investigation of drilling in ((0/90)/10)s glass
(2009) experimentally the significance of the fiber reinforced plastics using taguchi
drill point geometry and operating method
variables on the drilling forces and the
drilling induced damage
Design of Durãoa, Magalhãesa, Non Destructive inspection technique. Effect Of Drilling parameters on composite
Experiments Marquesb, João plates damage. A proper selection of tool
Manuel Tavaresb and drilling
(2007) parameters can reduce the risk of
delamination.

A review of literature shows that various traditional machining optimization techniques like Lagrange’s
method, geometric programming, goal programming, dynamic programming etc. have been successfully applied in
the past for optimizing the various machining process variables. Fuzzy logic, genetic algorithm, scatter search,

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INTERNATIONAL JOURNAL Of ACADEMIC RESEARCH Vol. 3. No. 3. May, 2011, II Part

Taguchi technique and response surface methodology are the latest optimization techniques that are being applied
successfully in industrial applications for optimal selection of process variables in the area of machining. In the
recent optimization technique Taguchi methods is latest design techniques widely used in industries for making the
product/process insensitive to any uncontrollable factors such as environmental variables. Taguchi approach has
potential for savings in experimental time and cost on product or process development and quality improvement.

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