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Optimization of machining parameters to minimize tool deflection in the end milling operation using Genetic Algorithm.

Optimization of cutting parameters is valuable in terms of providing high precision and efficient machining. One of the effects of cutting force in the end milling operation with low diameter tool (during metal cutting) is tool deflection. Assuming that machining errors mostly arise from tool deflection, attempt was made to optimize machining parameters using Genetic Algorithm (GA) so as to minimize tool deflection. In contrast to other optimizations in which machining time and cost are defined as the objective functions, our algorithm considers tool deflection as the objective function while surface roughness and tool life are the constraints. In order to verify accuracy of optimization, results were compared with those calculable based on the theoretical relationships, in terms of agreement to those obtained experimentally. The obtained results indicate that the optimized parameters are capable of machining the workpiece more accurately with better surface finish.