Glowworm swarm optimization (GSO) for optimization of machining parameters

This study proposes glowworm swarm optimization (GSO) algorithm to estimate an improved value of machining performance measurement. GSO is a recent nature-inspired optimization algorithm that simulates the behavior of the lighting worms. To the best our knowledge, GSO algorithm has not yet been used for optimization practice particularly in machining process. Three cutting parameters of end milling that influence the machining performance measurement, minimum surface roughness, are cutting speed, feed rate and depth of cut. Taguchi method is performed for experimental design. The analysis of variance is applied to investigate effects of cutting speed, feed rate and depth of cut on surface roughness. GSO has improved machining process by estimating a much lower value of minimum surface roughness compared to the results of experimental and particle swarm optimization.     

Electromagnetism-like algorithms for optimized tool path planning in 5-axis flank machining

Optimization of tool path planning using metaheuristic algorithms such as ant colony systems (ACS) and particle swarm optimization (PSO) provides a feasible approach to reduce geometrical machining errors in 5-axis flank machining of ruled surfaces. The optimal solutions of these algorithms exhibit an unsatisfactory quality in a high-dimensional search space. In this study, various algorithms derived from the electromagnetism-like mechanism (EM) were applied. The test results of representative surfaces showed that all EM-based methods yield more effective optimal solutions than does PSO, despite a longer search time. A new EM-MSS (electromagnetism-like mechanism with move solution screening) algorithm produces the most favorable results by ensuring the continuous improvement of new searches. Incorporating an SPSA (simultaneous perturbation stochastic approximation) technique further improves the search results with effective initial solutions. This work enhances the practical values of tool path planning by providing a satisfactory machining quality.     

Fuzzy approach to select machining parameters in electrical discharge machining (EDM) and ultrasonic-assisted EDM processes

Condition monitoring of the machining process is very important in today's precision manufacturing, especially in the electrical discharge machining (EDM). This paper introduces a fuzzy-based algorithm for prediction of material removal rate (MRR), tool wear ratio (TWR), and surface roughness (R_z, R_k) in the EDM and ultrasonic-assisted EDM (US/EDM) processes. In this system, discharge current, pulse duration, and ultrasonic vibration of tool are the input variables and outputs are MRR, TWR, R_z, and R_k. The proposed fuzzy model in this study provides a more precise and easy selection of EDM and US/EDM input parameters, respectively for the required MRR, TWR, R_z, and R_k, which leads to better machining conditions and decreases the machining costs. The fuzzy modeling of EDM and US/EDM were able to predict the experimental results with accuracies more than 90%.     

A new design of evolutionary hybrid optimization of SVR model in predicting the blast-induced ground vibration

This study aims to identify the suitability of hybridizing the firefly algorithm (FA), genetic algorithm (GA), and particle swarm optimization (PSO) with two well-known data-driven models of support vector regression (SVR) and artificial neural network (ANN) to predict blast-induced ground vibration. Here, these combinations are abbreviated using FA–SVR, PSO–SVR, GA–SVR, FA–ANN, PSO–ANN, and GA–ANN models. In addition, a modified FA (MFA) combined with SVR model is also proposed in this study, namely, MFA–SVR. The feasibility of the proposed models is examined using a case study, located in Johor, Malaysia. Then, to provide an objective assessment of performances of the predictive models, their results were compared based on several well known and popular statistical criteria. According to the results, the MFA–SVR with the coefficient of determination (R²) of 0.984 and root mean square error (RMSE) of 0.614 was more accurate model to predict PPV than the PSO–SVR with R² = 0.977 and RMSE = 0.725, the FA–SVR with R² = 0.964 and RMSE = 0.923, the GA–SVR with R² = 0.957 and RMSE = 1.016, the GA–ANN with R² = 0.936 and RMSE = 1.252, the FA–ANN with R² = 0.925 and RMSE = 1.368, and the PSO–ANN with R² = 0.924 and RMSE = 1.366. Consequently, the MFA–SVR model can be sufficiently employed in estimating the ground vibration, and has the capacity to generalize.

     

A standard deviation based firefly algorithm for multi-objective optimization of WEDM process during machining of Indian RAFM steel

Non-conventional machining processes always suffer due to their low productivity and high cost. However, a suitable machining process should improve its productivity without compromising product quality. This implies the necessity to use efficient multi-objective optimization algorithm in non-conventional machining processes. In this present paper, an effective standard deviation based multi-objective fire-fly algorithm is proposed to predict various process parameters for maximum productivity (without affecting product quality) during WEDM of Indian RAFM steel. The process parameters of WEDM considered for this study are: pulse current (I), pulse-on time (T _on), pulse-off time (T _off) and wire tension (WT).While, cutting speed (CS) and surface roughness (SR) were considered as machining performance parameters. Mathematical models relating the process and response parameters had been developed by linear regression analysis and standard deviation method was used to convert this multi objective into single objective by unifying the responses. The model was then implemented in firefly algorithm in order to optimize the process parameters. The computational results depict that the proposed method is well capable of giving optimal results in WEDM process and is fairly superior to the two most popular evolutionary algorithms (particle swarm optimization algorithm and differential evolution algorithm) available in the literature.

     

Artificial algae algorithm (AAA) for nonlinear global optimization

In this study, a novel bio-inspired metaheuristic optimization algorithm called artificial algae algorithm (AAA) inspired by the living behaviors of microalgae, photosynthetic species, is introduced. The algorithm is based on evolutionary process, adaptation process and the movement of microalgae. The performance of the algorithm has been verified on various benchmark functions and a real-world design optimization problem. The CEC’05 function set was employed as benchmark functions and the test results were compared with the algorithms of Artificial Bee Colony (ABC), Bee Algorithm (BA), Differential Evolution (DE), Ant Colony Optimization for continuous domain (ACO_R) and Harmony Search (HS_POP). The pressure vessel design optimization problem, which is one of the widely used optimization problems, was used as a sample real-world design optimization problem to test the algorithm. In order to compare the results on the mentioned problem, the methods including ABC and Standard PSO (SPSO2011) were used. Mean, best, standard deviation values and convergence curves were employed for the analyses of performance. Furthermore, mean square error (MSE), root mean square error (RMSE) and mean absolute percentage error (MAPE), which are computed as a result of using the errors of algorithms on functions, were used for the general performance comparison. AAA produced successful and balanced results over different dimensions of the benchmark functions. It is a consistent algorithm having balanced search qualifications. Because of the contribution of adaptation and evolutionary process, semi-random selection employed while choosing the source of light in order to avoid local minima, and balancing of helical movement methods each other. Moreover, in tested real-world application AAA produced consistent results and it is a stable algorithm.     

Elucidating multiprocessors flow shop scheduling with dependent setup times using a twin particle swarm optimization

Particle swarm optimization (PSO) is a novel metaheuristic, which has been applied in a wide variety of production scheduling problems. Two basic characteristics of this algorithm are its efficiency and effectiveness in providing high-quality solutions. In order to improve the traditional PSO, this study proposes the incorporation of a local search heuristic into the basic PSO algorithm. The new, hybrid, metaheuristic is called “twin particle swarm optimization (TPSO)”. The proposed metaheuristic scheme is applied to a flow shop with multiprocessors scheduling problem, which can be considered a real world case regarding the production line. This study, as far as the multiprocessors flow shop production system is concerned, utilizes sequence dependent setup times as constraints. Finally, simulated data confirm the effectiveness and robustness of the proposed algorithm. The data test results indicate that TPSO has potential to replace PSO and become a significant heuristic algorithm for similar problems.     

Stochastic convergence analysis and parameter selection of the standard particle swarm optimization algorithm

This letter presents a formal stochastic convergence analysis of the standard particle swarm optimization (PSO) algorithm, which involves with randomness. By regarding each particle's position on each evolutionary step as a stochastic vector, the standard PSO algorithm determined by non-negative real parameter tuple {ω,c₁,c₂} is analyzed using stochastic process theory. The stochastic convergent condition of the particle swarm system and corresponding parameter selection guidelines are derived.     

Introducing dynamic diversity into a discrete particle swarm optimization

Particle swarm optimization (PSO) is an evolutionary metaheuristic inspired by the flocking behaviour of birds, which has successfully been used to solve several kinds of problems, although there are few studies aimed at solving discrete optimization problems. One disadvantage of PSO is the risk of a premature search convergence. To prevent this, we propose to introduce diversity into a discrete PSO by adding a random velocity. The degree of the introduced diversity is not static (i.e. preset before running PSO) but instead changes dynamically according to the heterogeneity of the population (i.e. if the search has converged or not). We solve the response time variability problem (RTVP) to test these two new ideas. The RTVP is an NP-hard combinatorial scheduling problem that has recently appeared in the literature. It occurs whenever products, clients or jobs need to be sequenced in such a way that the variability in the time between the instants at which they receive the necessary resources is minimized. The most efficient algorithm for solving non-small instances of the RTVP published to date is a classical PSO algorithm, referred to by the authors as PSO-M1F. In this paper, we propose 10 discrete PSO algorithms for solving the RTVP: one based on the ideas described above (PSO  -_c3dyn$c_3\text{<italic>dyn</italic>}$) and nine based on strategies proposed in the literature and adapted for solving a discrete optimization problem such as the RTVP. We compare all 11 PSO algorithms and the computational experiment shows that, on average, the best results obtained are due to our proposal of dynamic control mechanism for introducing diversity.     

Application of improved firefly algorithm for programmed PWM in multilevel inverter with adjustable DC sources

Programmed pulse width modulation is an optimized pulse width modulation which is particularly applicable for high-power applications where the power losses must be kept below firm limits. Based on the offline estimation, it is capable of pre programming the harmonic profile of the output waveform over a range of modulation indices by eliminating some lower order harmonics. In this paper, improved firefly algorithm (FA) is applied to determine the optimum switching angles for the 11- level cascaded H bridge multilevel inverter (MLI) with adjustable DC sources in order to eliminate pre specified lower order harmonics and to achieve the desired fundamental voltage. Though number of optimization algorithms is available for the estimation of switching angles, Firefly algorithm takes least computation time and surpasses all other 11 metaheuristic Algorithms. The algorithm and the model are developed using MATLAB and the validity of the simulation is confirmed by an experimental setup using FPGA Spartan 6A DSP. Results are compared with the results obtained using particle swarm optimization (PSO) and artificial bee colony algorithm (ABCA) and it is proved that the proposed method offers reduced total harmonic distortion (THD) with less computation period.     

Artificial bee colony algorithm for small signal model parameter extraction of MESFET

This paper presents an application of swarm intelligence technique namely artificial bee colony (ABC) to extract the small signal equivalent circuit model parameters of GaAs metal extended semiconductor field effect transistor (MESFET) device and compares its performance with particle swarm optimization (PSO) algorithm. Parameter extraction in MESFET process involves minimizing the error, which is measured as the difference between modeled and measured S parameter over a broad frequency range. This error surface is viewed as a multi-modal error surface and robust optimization algorithms are required to solve this kind of problem. This paper proposes an ABC algorithm that simulates the foraging behavior of honey bee swarm for model parameter extraction. The performance comparison of both the algorithms (ABC and PSO) are compared with respect to computational time and the quality of solutions (QoS). The simulation results illustrate that these techniques extract accurately the 16—element small signal model parameters of MESFET. The efficiency of this approach is demonstrated by a good fit between the measured and modeled S-parameter data over a frequency range of 0.5–25 GHz.     

Monitoring the tool wear,surface roughness and chip formation occurrences using multiple sensors in turning

Tool wear, chip formation and surface roughness of workpiece under different cutting conditions have been investigated in machining using acoustic emission (AE) and vibration signature in turning. The investigation has shown that the AE and vibration components can effectively respond to the different occurrences in turning including tool wear and surface roughness. The AE has shown a very significant response to the tool wear progression whereas the resultant vibration (V) represented the surface roughness in turning. The vibration components V_x, V_y and V_z described the chip formation type and are found to have the most significant response to the change of feed, depth of cut and cutting speed respectively. The amplitude of vibration components, V_x, V_y and V_z increased with the increase of feed rate, depth of cut and cutting speed respectively. Even though the frequency of different signal components fluctuated at the different stages of tool wear and at different cutting conditions, the frequency of vibration components was always within a band of 98–40 kHz, and the AE has varied between 51 kHz and 620 kHz.     

Estimation of the minimum machining performance in the abrasive waterjet machining using integrated ANN-SA

In this study, Artificial Neural Network (ANN) and Simulated Annealing (SA) techniques were integrated labeled as integrated ANN-SA to estimate optimal process parameters in abrasive waterjet (AWJ) machining operation. The considered process parameters include traverse speed, waterjet pressure, standoff distance, abrasive grit size and abrasive flow rate. The quality of the cutting of machined-material is assessed by looking to the roughness average value (R_a). The optimal values of the process parameters are targeted for giving a minimum value of R_a. It was evidence that integrated ANN-SA is capable of giving much lower value of R_a at the recommended optimal process parameters compared to the result of experimental and ANN single-based modeling. The number of iterations for the optimal solutions is also decreased compared to the result of SA single-based optimization.     

Teaching and peer-learning particle swarm optimization

Most of the recent proposed particle swarm optimization (PSO) algorithms do not offer the alternative learning strategies when the particles fail to improve their fitness during the searching process. Motivated by this fact, we improve the cutting edge teaching–learning-based optimization (TLBO) algorithm and adapt the enhanced framework into the PSO, thereby develop a teaching and peer-learning PSO (TPLPSO) algorithm. To be specific, the TPLPSO adopts two learning phases, namely the teaching and peer-learning phases. The particle firstly enters into the teaching phase and updates its velocity based on its historical best and the global best information. Particle that fails to improve its fitness in the teaching phase then enters into the peer-learning phase, where an exemplar is selected as the guidance particle. Additionally, a stagnation prevention strategy (SPS) is employed to alleviate the premature convergence issue. The proposed TPLPSO is extensively evaluated on 20 benchmark problems with different features, as well as one real-world problem. Experimental results reveal that the TPLPSO exhibits competitive performances when compared with ten other PSO variants and seven state-of-the-art metaheuristic search algorithms.     

Digital twin-driven surface roughness prediction and process parameter adaptive optimization

In the process of parts machining, the real-time state of equipment such as tool wear will change dynamically with the cutting process, and then affect the surface roughness of parts. The traditional process parameter optimization method is difficult to take into account the uncertain factors in the machining process, and cannot meet the requirements of real-time and predictability of process parameter optimization in intelligent manufacturing. To solve this problem, a digital twin-driven surface roughness prediction and process parameter adaptive optimization method is proposed. Firstly, a digital twin containing machining elements is constructed to monitor the machining process in real-time and serve as a data source for process parameter optimization; Then IPSO-GRNN (Improved Particle Swarm Optimization-Generalized Regression Neural Networks) prediction model is constructed to realize tool wear prediction and surface roughness prediction based on data; Finally, when the surface roughness predicted based on the real-time data fails to meet the processing requirements, the digital twin system will warn and perform adaptive optimization of cutting parameters based on the currently predicted tool wear. Through the development of a process-optimized digital twin system and a large number of cutting tests, the effectiveness and advancement of the method proposed in this paper are verified. The organic combination of real-time monitoring, accurate prediction, and optimization decision-making in the machining process is realized which solves the problem of inconsistency between quality and efficiency of the machining process.     

具有量子行为的粒子群优化算法的改进

为改善基本粒子群的全局、局部搜索能力和收敛速度、计算精度,基于标准PSO算法和量子理论基础之上,提出一种改进的基于量子行为的PSO算法—WbQPSO算法。新算法中,采用全同粒子系更新位置,并引入混沌思想,对每个粒子进行混沌搜索,另外通过在Mbest_i中加入权重系数,试图改善粒子群的全局、局部搜索能力和收敛速度以及计算精度。对经典函数的测试计算表明：改进算法的性能优于经典的PSO算法,基于量子行为的PSO算法。     

A novel approach to CNC machining center processing parameters optimization considering energy-saving and low-cost

NC machining is currently a machining method widely used in mechanical manufacturing systems. Reasonable selection of process parameters can significantly reduce the processing cost and energy consumption. In order to realize the energy-saving and low-cost of CNC machining, the cutting parameters are optimized from the aspects of energy-saving and low-cost, and a process parameter optimization method of CNC machining center that takes into account both energy-saving and low -cost is proposed. The energy flow characteristics of the machining center processing system are analyzed, considering the actual constraints of machine tool performance and tool life in the machining process, a multi-objective optimization model with milling speed, feed per tooth and spindle speed as optimization variables is established, and a weight coefficient is introduced to facilitate the solution to convert it into a single objective optimization model. In order to ensure the accuracy of the model solution, a combinatorial optimization algorithm based on particle swarm optimization and NSGA-II is proposed to solve the model. Finally, take plane milling as an example to verify the feasibility of this method. The experimental results show that the multi-objective optimization model is feasible and effective, and it can effectively help operators to balance the energy consumption and processing cost at the same time, so as to achieve the goal of energy conservation and low-cost. In addition, the combinatorial optimization algorithm is compared with the NSGA-II, the results show that the combinatorial optimization algorithm has better performance in solving speed and optimization accuracy.     

Nonlinear inertia weight variation for dynamic adaptation in particle swarm optimization

The particle swarm optimization (PSO) is a relatively new generation of combinatorial metaheuristic algorithms which is based on a metaphor of social interaction, namely bird flocking or fish schooling. Although the algorithm has shown some important advances by providing high speed of convergence in specific problems it has also been reported that the algorithm has a tendency to get stuck in a near optimal solution and may find it difficult to improve solution accuracy by fine tuning. The present paper proposes a new variation of PSO model where we propose a new method of introducing nonlinear variation of inertia weight along with a particle's old velocity to improve the speed of convergence as well as fine tune the search in the multidimensional space. The paper also presents a new method of determining and setting a complete set of free parameters for any given problem, saving the user from a tedious trial and error based approach to determine them for each specific problem. The performance of the proposed PSO model, along with the fixed set of free parameters, is amply demonstrated by applying it for several benchmark problems and comparing it with several competing popular PSO and non-PSO combinatorial metaheuristic algorithms.     

Parametric appraisal and optimization in machining of CFRP composites by using TLBO (teaching–learning based optimization algorithm)

The present paper focuses on machining (turning) aspects of CFRP (epoxy) composites by using single point HSS cutting tool. The optimal setting i.e. the most favourable combination of process parameters (such as spindle speed, feed rate, depth of cut and fibre orientation angle) has been derived in view of multiple and conflicting requirements of machining performance yields viz. material removal rate, surface roughness, SR \((\hbox {R}_{\mathrm{a}})\) (of the turned product) and cutting force. This study initially derives mathematical models (objective functions) by using statistics of nonlinear regression for correlating various process parameters with respect to the output responses. In the next phase, the study utilizes a recently developed advanced optimization algorithm teaching–learning based optimization (TLBO) in order to determine the optimal machining condition for achieving satisfactory machining performances. Application potential of TLBO algorithm has been compared to that of genetic algorithm (GA). It has been observed that exploration of TLBO appears more fruitful in contrast to GA in the context of this case experimental research focused on machining of CFRP composites.