CNC micromilling properties and optimization using genetic algorithms

Micromachining operations are mainly restricted to precision machining of two-dimensional microparts, usually performed on microelectrical discharge machining or microlaser computer numerical control (CNC) machine tools. However, micromilling can fully exploit computer-aided design/computer-aided manufacturing (CAM) software abilities, in order to achieve more complex three-dimensional micropart geometries. After fully defining the micromilling process parameters and related constraints, optimization methodologies, such as genetic algorithms, can be coupled with CAM software, thus obtaining optimal process parameters with very small calculation cost. In this study, CNC micromilling process is systematically presented, along with respective micromilling tools and the necessary industrial equipment for the processes. Genetic algorithm code was developed in Visual Basic, which optimizes the process and ultimately yields optimal parameter values, including all process particulars. Two test cases were presented, and results were discussed in terms of micropart quality, production time, and calculation cost.