METALS AND MATERIALS International, Vol. 8, No. 2 (2002), pp.

163~168

Optimization of Drilling Characteristics for Al/SiCp Composites Using Fuzzy/GA

R. Karthikeyan, S. Jaiganesh and B. C. Pai* Department of Production Engineering, Annamalai University Annamalainagar 608 002, India *Regional Research Laboratory, Thiruvananthapuram, India
In this paper an attempt has been made to optimize the drilling characteristics for Al/SiCp composites using fuzzy logic and genetic algorithms (GA). The drilling characteristics studied were drill wear, specific energy and surface roughness. The parameters considered for the study include volume fraction of SiC in the aluminium matrix, cutting speed and feed rate. The experimental data was trained and simulated using fuzzy logic and optimization of cutting conditions were performed using genetic algorithms. The optimized cutting conditions were validated using confirmation experiments. Keywords : metal matrix composites, drilling, optimization, fuzzy logic, genetic algorithms

1. INTRODUCTION
Metal matrix composites are materials which combine a tough metallic matrix and a hard ceramic reinforcement to produce composite materials with superior properties to conventional metallic alloys [1]. Although the addition of ceramic particles has been shown to produce materials with improved properties, the machining of these materials has been a serious problem due to the abrasiveness of the reinforcement phase [2]. To improve the machinability of these materials, the processing conditions need to be optimized and a machining database is required [3]. Conventional statistical techniques have been traditionally used for the modeling and optimization of machining characteristics. More recently the focus is on artificial intelligence tools such as fuzzy logic, neural network and genetic algorithm for modeling and optimization [4]. The fuzzy system is a rule-based system, which is built on fuzzy logic and fuzzy set theory. In a fuzzy system, the partitions may overlap and a point in the input space may belong to more than one partition. The models developed based on fuzzy logic deal with linguistic variables rather than crisp values [5]. Further, the inference mechanisms found in the fuzzy logic controller are generally simpler than those employed in traditional expert systems [6]. The traditional search techniques are calculus based and converge only to a local optimum. Genetic algorithm (GA) is a guided random search technique and is directed through the search space by means of an objective function. The GA has been used in the area of machining in the drilling of MMCs [7], face milling [8] and multi-pass turning [9]. The

integration of fuzzy logics and genetic algorithm was found to be effective for modeling and simulation [10]. Hence, it is proposed to use fuzzy models for the prediction of drilling characteristics of Al/SiC composites and the genetic algorithm for optimization of process parameters.

2. METHODOLOGY
The experiments were conducted by varying speed, feed rate and volume fraction of SiC present in the aluminium matrix. The outputs studied were tool wear, specific energy and surface roughness. The tool used was a SANDWICK solid carbide drill 10mm diameter in size. The work piece machined was LM25 aluminium alloy reinforced with green bonded SiC particles 25 m in size. The drilling tests were conducted on a B&W radial drilling machine. The tool wear was measured using VERSAMET optical microscope after a drilling time of 10 minutes. The specific energy was determined as the ratio of net power to metal removal rate, the power consumed estimated using a MECO-G single-phase two-watt meter, and the centerline average of surface roughness determined using a Talysurf III recorder. The experimental results were used to form fuzzy rules relating the various inputs and outputs. The fuzzy modeling was performed for prediction of outputs. The genetic algorithm was linked with the fuzzy inference engine to optimize the machining conditions for the desired goals. The objectives of the present study include maximizing the metal removal rate (MRR) and minimizing tool wear, specific energy and surface roughness. Goals were fixed for each objective by using




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statistical means of the experimental results. The optimized machining conditions (speed and feed rate) were obtained using the fuzzy-genetic algorithm hybrid technique (GA_FU) for different volume fraction composites.

3. GA_FU ALGORITHM
The different steps involved in the proposed algorithm (GA_FU) are given below. 1. This involves training the fuzzy rule base using the experimental data. Once it is trained, it is ready for simulating flank wear, specific energy and surface roughness. 2. The modeling part required for GA is satisfied by the trained fuzzy rule base. This involves the interface of GA with fuzzy. 3. This step involves giving input to GA, such as number

of generations (N_Gen), population size (pop_size), number of inputs, their ranges and goal values. GA Creates pop_size times input and simulates output using fuzzy. 4. The deviation between goal values and simulated values are minimized after each iteration by the process of selection of input in a random manner. 5. Finally, the optimized machining conditions are produced after completing N_Gen number of iterations along with optimized input values, current deviations and fixed goals. The combined algorithm was given in Fig. 1.

4. IMPLEMENTATION
Fuzzy Logic Modeling The basic steps involved in the fuzzy logic modeling are as follows. Step 1: Defining input and output The ranges for the variables that represent the relevant conditions of the given process are identified. The range of input and output values is called the universe of discourse or dimension. These are shown in Table 1. Step 2: Fuzzify the input and output Meaningful linguistic statements are selected for each variable and expressed by appropriate fuzzy sets (Table 2). The fuzzification for the volume of SiC percentage is shown in Fig. 2. Similarly, all the input and out variables are fuzzified. The change of states (eg. very low to low), is assumed to be continuous and is represented by the set of overlapped triangles. Step 3: Creating a fuzzy rule base From the analysis of the experimental results, a fuzzy rule
Table 2. Fuzzification of volume fraction of SiC Fuzzy variable Very low Low Medium High Very high Crisp input range 0-10 5-15 10-20 15-20 20-30

Fig. 1. Flow chart for FU_GA algorithm.

Table 1. Ranges for input and output Process parameter Volume of SiC Speed, rpm Feed rate, mm/rev Flank wear, mm 3 Specific energyW/mm /min Surface roughness, m Input/Output Input Input Input Output Output Output Minimum value 0 300 0 0 0 2 Maximum value 30 1600 0.55 1.2 0.11 17

Optimization of Drilling Characteristics for Al/SiCp Composites Using Fuzzy/GA



Fig. 2. Fuzzification of input parameter vol.% of SiC. Fig. 3. Defuzzification using centroid method.

base consisting of IF-THEN rules was created. A total of 375 (125X3) rules were formed for the three types of outputs using experimental results and incorporated in the knowledge base. Step 4: Defuzzification for the crisp output The main step is defuzzification of the output into a crisp value. There are several strategies for this; among them the most common method is the center of area or centroid method. For example, the input conditions are volume of SiC (10%), speed (1500 rpm), feed (0.22 mm/rev). After fuzzification, volume of SiC is low (1), speed is very high (0.47) and feed is low (0.4) and medium (0.2667). This requires two fire rules. i. IF Vol. Of SiC is low (1) AND speed is very high (0.4) AND feed is low (0.4) THEN flank wear is high. ii. IF Vol. Of SiC is low (1) AND speed is very high (0.4) AND feed is medium (0.2667) THEN flank wear is high. The firing strengths of the rules are determined for the two rules by the conjection or minimum operator as follows. For Rule 1:1 ^ 0.4 ^ 0.4=0.4 of category high for flank wear. For Rule 2: 1 ^ 0.4 ^ 0.2667=0.2667 of category high for flank wear. Using the centroid method, the flank wear was obtained as 0.62 mm (Fig. 3). Tables 3-5 below show that the output predicted by the fuzzy is close to actual experimental output.

over operator or mutation operator. Merging two chromosomes from the current generation is called a cross over operation and modification of the chromosome by changing 0 to1 in the binary state is called a mutation operation. A new generation is formed by selecting some of the parents and offspring based on the fitness function values. After several generations, the algorithm converges to the best chromosome that hopefully represents the optimal solution to the problem.

6. ALGORITHM
Step 1: Parameter setting Max. number of generations Population size Probability of cross over Probability of mutation A large positive number Current generation Step 2: Initialisation process Given an interior point Vo for K 1 pop_size Do M Mo Produce a random direction d Vk Vo+M.d while (Vk is not feasible) do M random (M) Vk Vo+M.d end Setp 3: Evaluation for K 1 to pop_size do Compute objectives Fk for Vk by FUZZY simulation end Rank chromosomes according to objectives for K 1 to pop_size do Compute exponential fitness (eval Vk) end : M_gen : pop_size : Pc : Pm : Mo : N_gen 0

5. OPTIMIZATION
The GA is interfaced with fuzzy for optimization. The genetic algorithm starts with an initial set of random solutions called population. Each individual in the population is called a chromosome representing a solution to the problem at hand. A chromosome is a string of symbols, which is usually, but not necessarily a binary bit string. The chromosomes obtained through successive iterations are called generations. During each generation, the chromosomes were evaluated using measures of fitness. To create the next generation, new chromosomes called offspring are formed by a cross



Step 4: Selection operation for K 1 to pop_size do Compute the selective probabilities pop_size Pk=eval (Vk) / eval (Vj) j=0 end for K 1 to pop_size do Compute cumulative probabilities k Qk = Pj j=1 end for K 1 to pop_size do if Qk-1 < random ( ) <= Qk then select Vk end Step 5: Cross over operation for K 1 to pop_size if (random ( ) <=Pc) then j random (pop_size) l random (pop_size) random ( ) V Vj + (1-a) Vi V Vi + (1-a) Vj end Step 6: Mutation operation for K 1 to pop_size do if random ( ) <=Pm) then M Mo Produce a random direction d Vk Vk+M.d While (Vk is not feasible) do M random (M) Vk Vk +M end Step 7: Termination set N_gen N_gen+1 if (N_gen <M_gen) then goto step 2 else

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stop end The inputs to the FU_GA software and the output are shown below. 6.1. Input data 1. Enter number of generations: 50 2. Enter the even pop_size and input total: 10 3 3. Enter the minimum range and maximum range for inputs a. Enter range for item 0: 10 10 b. Enter range for item 1: 400 1500 c. Enter range for item 2: 0.2 0.5 4. Enter the random direction for each input to generate number of input values a). Enter the random direction for 0: 0 b). Enter the random direction for 1: 1 c). Enter the random direction for 2: 0.01 5. Enter the goal values for outputs a. Enter [0]: 5579 b. Enter [1]: 0.46 c. Enter y [2]: 0.03943 d. Enter y [3]: 8.5 6. Enter seed value for random number generation for selection of chromosome: 0.123 7. Enter crossover probability to merge chromosomes: 0.5 8. Enter the interior point of input values (Vo) and large positive number (Mo) for each input to generate pop_size chromosomes a. Enter Vo [0]: 10 Enter Mo [0]: 10 b. Enter Vo [1]: 910 Enter Mo [1]: 20 c: Enter Vo [2]: 0.249 Enter Mo [2]: 10 6.2. Output data For volume fraction of 10%, the optimum speed and feed rate are 921.0 rpm and 0.258 mm/rev The optimized output values are Metal removal rate=5579.0 mm3/min, Drill wear=0.460 mm, Specific energy=0.03943 W/mm3/min and Surface roughness =8.50 m For the above conditions, no deviation was noticed from the fixed goals.
Table 3. Prediction vs experimental results flank wear

Volume of SiC 10 15 10 15

Drill speed, rpm 700 700 1100 700

Feed rate, mm/rev 0.1 0.1 0.1 0.2

Flank wear mm Experimental value 0.38 0.41 0.43 0.51 Simulated value 0.4 0.4 0.41 0.6

Optimization of Drilling Characteristics for Al/SiCp Composites Using Fuzzy/GA

Table 4. Prediction vs experimental results specific energy Volume of SiC 10 15 10 15 Drill speed, rpm 700 700 1100 700 Feed rate, mm/rev 0.1 0.1 0.1 0.2 Specific energy W/mm /min Experimental value 0.03281 0.04388 0.02490 0.05607 Simulated value 0.03000 0.04500 0.02850 0.06000
3



Table 5. Prediction vs experimental results surface roughness Volume of SiC 10 15 10 15 Drill speed, rpm 700 700 1100 700 Feed rate, mm/rev 0.1 0.1 0.1 0.2 Surface roughness m Ra Experimental value 7.9 6.61 6.10 7.87 Experimental value 7.9 6.61 6.10 7.6

Table 6. Consolidated optimum results Volume fraction of SiC% 5 10 15 20 25 Speed rpm 1023 921 880 800 715 Feed mm/rev 0.239 0.258 0.30 0.44 0.42 MRR mm /min 8401 5579 4412 3412 2861
3

Flank wear mm 0.4 0.46 0.53 0.6 0.68

Specific energy 3 W/mm /min 0.0255 0.0394 0.0521 0.0637 0.073

Surface rough. m 10.6 8.5 7.76 6.32 6.08

Similarly for different values of volume fraction, the optimum results were obtained using FU_GA software, as shown in Table 6.

7. EXPERIMENTAL VALIDATION
By conducting experiments with approximate optimized values of speed and feed rate for 10% volume fraction composites, the experimental results were found to be close to the optimized goal values with minimum deviations as shown in Table 7.

8. DISCUSSION
The FU_GA algorithm is found to be effective in the modeling and optimization of drilling characteristics of Al/SiC composites. Tables 3-5 show that the predicted values by fuzzy inference engine are found to be close to the experi-

mental results. This approach can be easily employed to select process parameters from a wider range with the addition of rules in the inference engine of the fuzzy model. Thus the approach is more flexible when compared to other models developed based on the experimental results that constrain their applicability of selecting the process parameters from a limited range. The genetic algorithm approach used here considers a number of objectives such as maximizing the MRR, minimizing tool wear, specific energy and surface roughness. Goals were fixed for each objective and overall deviation from the goals was minimized by generating a number of input patterns in a random manner. Table 6 shows the consolidated optimum solution obtained through the FU_GA approach. The optimum speed was found to decease with an increase in the volume fraction of SiC. This may be attributed to the increase in the abrasion rate of SiC particles with a tool that in turn results in tool wear. As the volume fraction of SiC increases, the specific energy would increase due to

Table 7. Experimental validation 10 vol.% of SiC Output values Attained goal values Experimental results Error % MRR mm /min 5579 6040 7.6
3

Flank wear mm 0.46 0.45 2.17

Specific energy W/mm /min 0.03943 0.03824 3.01

Surface rough. m 8.5 8.027 5.56




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an increase in hardness and strength that impede the tool penetration. Hence, for higher volume fraction composites, lower speeds are to be employed. An increase in the feed rate would increase the MRR and, on the other hand, the tool wear and specific energy would also increase due to an increase in area of contact between the drill and work. However, the effect of feed rate on wear will be less pronounced when compared with speed. Hence, it can be seen that the optimum feed rate decreases with an increase in the volume fraction of SiC. Table 7 shows that the experiments conducted at approximated optimum machining conditions have results close to the achieved values from the developed algorithm. Hence, the FU_GA algorithm can be used for the modeling and optimization of drilling characteristics of Al/ SiC composites.

validated with that obtained by experimental results.

ACKNOWLEDGMENT
The authors are grateful to Regional Research Laboratory, Thiruvananthapuram, India for supplying composite materials and All India Council for Technical Education for sponsoring the research through the TAPTEC Programme.

REFERENCES
1. T. W. Clyne and P. J. Withers, An Introduction to Metal Matrix Composites, Cambridge Univ. (1993). 2. A. R. Chambers, Composites A 27, 143 (1996). 3. S. Barnes and I. R. Pashby, Trans. ASME 122, 384 (2000). 4. V. T. Chen and S. R. T. Kumara, Int. J. of Production Res. 36, 395 (1998). 5. M. Gen and R. Cheng, Genetic Algorithms and Engineering Design, John Wiley (1994). 6. K. L. Choy and W. K. Chan, Proc. of IMCC 98, p. 226, Singapore (1998). 7. J. P. Davim and C. A. C. Antanio, Int. J. of Machine Tools and Manufact. 41, 21 (2001). 8. M. S. Shunmugam, S. V. B. Reddy and T. T. Narendran, Int. J. of Machine Tools and Manufact. 40, 401 (2000). 9. G. C. Onwubolu and T. Kumalo, Proc. of Institution of Mech. Eng. Part B 215, 117 (2001). 10. P. S. Chakravarthy and N. R. Babu, Mater. Manufact. Proc. 14, 581 (1999).

9. CONCLUSION
A fuzzy logic based expert system has been developed for modeling and simulation of a drilling process, considering uncertainties while predicting the machinability parameters. The genetic algorithm is an adaptive search technique that can be used to tackle the hard combinatorial optimization problems The software FU_GA can be used for the modeling and optimization of drilling characteristics of Al/SiC composites. The optimized conditions can be used to improve the machinability of Al/SiC composites. The solution obtained by the proposed methodology is