Evolutionary Optimization of Machining Processes

Optimization of machining processes plays a key role in meeting the demands for high precision and productivity. The primary challenge for machining process optimization often stems from the fact that the procedure is typically highly constrained and highly non-linear, involving mixed-integer-discrete-continuous design variables. Additionally, machining process models are likely discontinuous, non-explicit, or not analytically differentiable with the design variables. Traditional non-linear optimization techniques are mostly gradient-based, posing many limitations upon application to today’s complex machining models. Genetic Algorithms (GAs) has distinguished itself as a method with the potential for solving highly non-linear, ill-behaved complex machining optimization problems. Unlike traditional optimization techniques, GAs start with a population of different designs and use direct search methods stochastically and deterministically toward optimal and feasible direction. However, GAs still has its own drawbacks when it is applied to machining process optimization, including the lack of efficiency due to its binary representation scheme for continuous design variables, a lack of local fine-tuning capabilities, a lack of a self-adaptation mechanism, and a lack of an effective constraint handling method. A novel and systematic evolutionary algorithm based on GAs is presented in this paper in the areas of problem representation; selection scheme; genetic operators for integer, discrete, and continuous variables; constraint handling method; and population initialization to overcome the underlying drawbacks. The proposed scheme has been applied to two machining problems to demonstrate its superior performance.