Optimization for Engineering Problems

4Optimization of Cutting Parameters during Hard Turning using Evolutionary Algorithms

Optimum selection of cutting conditions drastically contributes to the increase of productivity and the reduction of costs; therefore, determination of optimum cutting parameters to minimize total machining time and process cost is the most essential task in cutting processes. This matter is more critical in hard turning in which the costs of machining are higher because of high tool wear rate. Efficiency and productivity of hard turning can be enhanced impressively by using accurate predictive models for cutting tool wear. The ability of genetic programming to present an accurate analytical model is a notable characteristic, which makes it more applicable than other predictive modeling methods. In this chapter, a novel intelligence-based methodology for calculating optimum cutting parameters in hard turning of AISI D2 is proposed. In the first step, the genetic equation for the modeling of tool flank wear is developed with the use of the experimentally measured flank wear values and genetic programming. In this order, a series of tests were conducted over a range of cutting parameters and the values of tool flank wear were measured. Using the obtained results, genetic models presenting connections between cutting parameters and tool flank wear are extracted. In the second step, based on the defined machining performance index and the obtained genetic equation, optimum cutting parameters ...