OPTIMISATION OF SURFACE

FINISH USING GENETIC

ALGORITHM AND EXPERIMENTAL
VALIDATION FOR END -
MILLING OPERATIONS
 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 obtain better surface finish. The
machining parameters are:-
•Cutting Speed
•Feed per tooth
•Depth of cut
 OBJECTIVE FUNCTION
• The purpose of this study is to investigate the optimal
cutting parameters for minimizing machining time and
maximizing surface finish of the milling operation using
genetic algorithm while maintaining material removing
rate and stability of the process and experimental
validation is need to be done to estimate surface
roughness using experimental data.
 INTRODUCTION
Importance of Machining

Machining is the most important of the manufacturing processes.

Machining can be defined as the process of removing material from a work
piece in the form of chips. The term metal cutting is used when the
material is metallic. Most machining has very low setup cost compared to
forming, molding, and casting processes. However, machining is much
more expensive for high volumes. Machining is necessary where tight
tolerances on dimensions and finishes are required.
END-MILLING
End-milling process is used to machine and produce a
flat surface or a pair of flat surfaces. When the
operation is performed at the end of a work piece, as
shown in fig, a single flat surface is produced. The
surfaces produced may be horizontal, vertical or inclined
with respect to the top of the machine table.

APPLICATIONS
1.Profile milling
2.Tracer milling
3.Face milling
4.Plunging
 GENETIC ALGORITHM

A genetic algorithm (GA) is a search technique used

in computing to find exact or approximate solutions to
optimization and search problems. Genetic algorithms
are categorized as global search heuristics. Genetic
algorithms are a particular class of evolutionary
algorithms (EA) that use techniques inspired by
evolutionary biology such as inheritance, mutation,
selection, and crossover.
 Mathematical 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. A basic dynamic model of 2-DOF end milling with a flexible tool is
illustrated in Fig. 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 parameters are the spindle
speed N, the feed per tooth (chip load) if, the radial depth-of-cut br and the axial
depth of cut b. In development of a dynamic force model for end milling, the
objective of this study is to combine the concept of the equivalent orthogonal cutting
conditions with the concept of a regenerative force model to predict the cutting force.
 DETERMINATION OF CUTTING FORCES

The tooth of a milling cutter can be viewed as

a single point tool referring to a rotating
coordinate system; hence, the cutting force in
milling can be calculated from a predictive
force model as presented in Fig. 1 from cutting
conditions, the property of the work material,
the tool geometry and the corresponding
instantaneous dynamic re-generative
undeformed chip thickness. Consider the case
of up milling with an assumed circular tool
path. The cutter is subjected to normal and
tangential cutting force components which
may be projected into x and y coordinate
directions using rotational positioning of
cutting edge φ.
1.The tangential force Ft is proportional to the material dependent specific force Ks, the
feed per tooth f, the chip width b, and the rotational position of cutting edge ϕ.

2. The normal radial force is assumed proportional to tangential force Fn

where kt is the cutting force coefficient. Resolving Ft and FN into cutting forces in the x and
y direction and summing for all the teeth engaged will result in
Substitution of Eqs. 1 and 2 into Eqs. 3 and 4 yields x and y cutting forces, each with three
distinct terms: depth of cut b, sine and cosine of φ. Equations 5 and 6 can be rewritten as

Where z is the number of teeth on the cutter. The x and they cutting force components
given in Eqs. 5 and 6 may be evaluated analytically for the optimized cutting parameters
and compared with measured values.