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Moth-flame optimization
algorithm to determine optimal
machining parameters in
manufacturing processes
Betül Sultan Yıldız and Ali Rıza Yıldız, In this research, a newly developed moth-flame optimiza-
Materials Testing downloaded from www.hanser-elibrary.com by Hanser - Library on May 4, 2017
Milling and turning are two commonly In this publication, the moth-flame opti- tioned parameters is related to the work-
used machining operations in manufactur- mization algorithm (MFO) is used to opti- piece geometry and process sequence. It is
ing industry. Milling is a process of remov- mize cutting parameters in milling opera- recommended to machine the features in a
ing chips from a fixed workpiece using a tions. The MFO is applied to a well-known single pass at the desired depth to keep
cutter that rotates about its axis. Determi- case study [15] to optimize the machining machining time and cost low. For this rea-
nation of the optimum manufacturing pa- parameters in milling operations. The re- son, the problem of determining machining
rameters is very important in order to de- sults show that the MFO is more effective parameters is reduced in order to achieve
velop the quality of the products and to than cuckoo search algorithm [2], ant col- the appropriate combination of cutting
enhance the total profit rate in manufactur- ony algorithm [7], handbook recommenda- speed and feed rate [15]. In this research, a
ing industry. tions [13], feasible direction method [15], mathematical model developed by Rad and
When the research works in the litera- hybrid particle swarm [22], genetic algo- Bidhendi [15] is considered for optimiza-
ture are examined in detail, it is seen that rithm [26] and hybrid immune algorithm tion of milling problems.
the first study on optimal cutting parame- [26] to optimize the cutting parameters for A case study related to milling operation
ters was carried out in the 1900 s [1]. After milling operations. is presented in this paper. The aim of the
that, different optimization techniques [1- case study is to maximize the total profit rate
10] have been preferred for defining opti- Optimization model of considering unit production time and unit
mum machining parameters in literature. multi-tool milling operations production cost. The unit cost used in this
When these optimization techniques are problem is the sum of material cost, setup
used, they usually either get caught in the Three parameters which are depth of cut, cost, machining cost and tool changing cost.
local minimum or take a long time to find feed rate and cutting speed have the big- The unit cost is defined as follows [15]:
an optimal result [11]. gest influence on the productivity of a cut-
It is seen that population-based methods ting operation and cost. First of the men- see Equation 1 (1)
are used in many applications instead of tra-
ditional techniques in recent years [14-36].
m m
Tolouei-Rad and Bidhendi [15] have pre- Cu = cmat + (cl + c0 )t s + ∑ i=1(cl + c0 )K1i Vi−1fi−1 + ∑ cti K3 i Vi(1/n)−1fi[(w+g)/n]−1 + ∑ (cl + c0 )
m
⎡ F F2,1 … … F1,d ⎤
The unit time is calculated as follows: The surface finish limitation for end mill- ⎢ 1,1 ⎥
m m ing should be defined as: ⎢ F F2,2 … … F2,d ⎥
Tu t s + ∑ K1i Vi−1fi−1 + ∑ t ci M = ⎢ 2,1 ⎥ (15)
(2) ⎢ ! ! ! ! ! ⎥
i=1 i=1 C6 f2 ≤ 1 (8) ⎢ F Fn,2 … … Fn,d ⎥
⎢⎣ n,1 ⎥⎦
The total profit rate is calculated as follows: with
318(4d)−1 It is also assumed that there is an array for
S p − Cu C6 =
Pr = (3) storing the corresponding fitness values as
R a(at)
Tu (9) follows:
C5 Vf0.8 ≤ 1 (4) R a(at) In the MFO, both moths and flames are
the solution. The moths are the real search
with The cutting force constraint can be defined as: agents who move around the search area,
while the flames represent the best posi-
0.78K p Wzarada
C5 = (5) C8 Fc ≤ 1 (12) tion of the moths obtained so far. In other
60πdePm words, flames can be seen as flags or pins
Moth-flame thrown by moths when looking for a search
The surface finish value for both plain mill- optimization algorithm space. For this reason, each moth searches
ing and end milling operations should be around a flag (flame) and updates it to find
defined as: Moth-flame optimizer is a newly developed a better solution. With this mechanism, a
For personal use only.
optimization method. It is first introduced moth keeps the best solution [36].
f2 by Mirjalili in 2015 [36]. In the MFO algo- More detailed information about MFO al-
R a = 318 (6)
4d rithm, candidate solutions are assumed to gorithm can be found in [36].
be moths and variables of a problem are as-
and for face milling sumed to be positions of moths in the search A case study for
space. For this reason, they can fly in a 1-di- milling operation
f mensional, 2-dimensional, 3-dimensional or
R a = 318 (7)
tan(la) + cot(ca) hyperdimensional area by changing the po- In this case study, a component shown in
sition vectors. The MFO algorithm is a popu- Figure 1 is produced using CNC milling.
lation-based algorithm. Therefore, the set of The aim of this process is to obtain the op-
moths is represented in a matrix as follows: timum machining parameters for maximiz-
ing the profit rate. Basic features of ma-
⎡ m m2,1 … … m1,d ⎤ chine, material and constants are given
⎢ 1,1 ⎥
⎢ m m2,2 … … m2,d ⎥ below [15]:
M = ⎢ 2,1 ⎥ (13)
⎢ ! ! ! ! ! ⎥
⎢ m Sp = $ 25
mn,2 … … mn,d ⎥ cmat = $ 0.50
⎢⎣ n,1 ⎥⎦
co = $ 1.45 per min
with: number of moths and d: number of cl = $ 0.45 per min
design variables. ts = 2 min
For all the moths, it is assumed that tct = 0.5 min
there is a set of proper fitness values stored C = 33.98 for HSS tools
as follows: w = 0.28
C = 100.05 for carbide tool
⎡ OM ⎤ Kp = 2.24
⎢ 1 ⎥
⎢ OM ⎥ W = 1.1
OM = ⎢ 2
⎥ (14) n = 0.15 for HSS tools
⎢ ! ⎥ n = 0.3 for carbide tool
⎢ OM ⎥
⎣ n ⎦ g = 0.14
59 (2017) 5
PRODUCTION-ORIENTED TESTING 427
Material data: The results show that the MFO is more operation problem. The results of moth-
effective than cuckoo search algorithm flame algorithm, cuckoo search algo-
Quality: 10L50 leaded steel [2], ant colony algorithm [7], handbook rithm, hybrid immune algorithm, ant col-
Hardness = 225 BHN recommendations [13], feasible direction ony algorithm, genetic algorithm, feasible
method [15], hybrid particle swarm [22], direction method and handbook recom-
The speed and feed rate limits for five op- genetic algorithm [26] and hybrid im- mendations are compared. The results
eration types in the case study are listed in mune algorithm [26] in milling opera- show that the MFO is an important alter-
Table 1. tions. native in the optimization of manufactur-
The part shown in Figure 1 includes four ing problems.
machining features which are step, pocket Conclusions
and two slots. Five operations listed in Ta- References
ble 2 are required in order to produce the In this publication, the moth-flame opti-
1 F. W. Taylor: On the Art of Cutting Metals,
part shown in Figure 2. mization algorithm has been successfully Trans. American Soc. Mech. Engineers 28
The tool types for each operation and the used for the determination of optimum (1907), No. 37
required data for the tools are presented in machining parameters in milling opera- 2 A. R. Yıldız: Cuckoo search algorithm for the
Table 3. tions. The objective function used in the selection of optimal machining parameters in
The results given in Table 4 show that optimization is to maximize profit rate. milling operations, International Journal of
Advanced Manufacturing Technology 64
Materials Testing downloaded from www.hanser-elibrary.com by Hanser - Library on May 4, 2017
the maximization of the total profit rate in The MFO is effectively implemented in
(2013), pp. 55-61
milling operation is achieved by the MFO. the optimization process of the milling
DOI:10.1007/s00170-012-4013-7
3 E. J. A. Armarego, A. J. R. Simith, J. Wang:
Computer-aided constrained optimisation
Operation No. Operation type Speed limits (m × min-1) Feed rate limits (mm per tooth) analyses strategies for multipass helical tooth
1 Face milling 60–120 0.05–0.4 milling operation, Annals of the CIRP 43
(1994), No. 1, pp. 437-442
2 Corner milling 40–70 0.05–0.5 DOI:10.1016/S0007-8506(07)62248-3
3 Pocket milling 40–70 0.05–0.5 4 E. J. A. Armarego, A. J. R. Smith, J. Wang:
Constrained optimization strategies CAM
4 Slot milling 1 30–50 0.05–0.5
For personal use only.
59 (2017) 5
428 PRODUCTION-ORIENTED TESTING
tions, International Journal of Machine Tools & DOI:10.1016/j.jmatprotec.2008.06.028 FF, FR, FT Feed, radial and tangential forces
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conditions with practical constraints, Interna- Artificial Intelligence 26 (2013), pp. 327-333 K Distance to be travelled by the tool
tional Journal of Production Research 30 DOI:10.1016/j.engappai.2012.05.014 to perform the operation (mm)
(1992), No. 12, pp. 2907-2919 29 B. S. Yildiz: A comparative investigation of Ki (i = 1-3) Coefficients carrying constant values
DOI:10.1080/00207549208948198 eight recent population-based optimisation Kp Power constant depending on work-
17 S. Srisompom, S. Bureerat: Geometrical design algorithms for mechanical and structural piece material
of plate-fin heat sinks using hybridization of design problems, International Journal of la Lead (corner) angle of the tool
MOEA and RSM, IEEE Transactions on Compo- Vehicle Design, 73 (2017), pp. 208-218 m Number of machining operations
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nents and Packaging Technologies 31 (2008), DOI:10.1504/IJVD.2017.10003412 required to produce the product
No. 2, pp. 351-360 30 B. S. Yildiz, H. Lekesiz, A. R. Yildiz: Structural N Spindle speed (rev × min-1)
DOI:10.1109/TCAPT.2008.916799 design of vehicle components using gravitational n Tool life exponent
18 A. R. Yıldız: A comparative study of popula- search and charged system search algorithms, P, Pm Required power for the operation,
tion-based optimization algorithms for turning Materials Testing 58 (2016), No. 1, pp. 79-81 motor power (kW)
operations, Information Sciences 210 (2012), DOI:10.3139/120.110819 Pr Total profit rate ($ × min-1)
pp. 81-88 31 A. R. Yildiz: Optimal structural design of Q Contact proportion of cutting edge
DOI:10.1016/j.ins.2012.03.005 vehicle components using topology design with workpiece per revolution
19 J. Wang, T. Kuriyagawa, X. P. Wei, D. M. Guo: and optimization, Materials Testing 50 (2008), R Sale price of the product excluding
Optimization of cutting conditions for single No. 4 , pp. 224-228 material, setup and tool changing
pass turning operations using a deterministic DOI:10.3139/120.100880 costs ($)
approach, International Journal of Machine 32 A. R. Yildiz, N. Kaya, O. B. Alankus, F. Ozturk: Ra, Ra(at) Arithmetic value of surface finish,
Passs and Manufacture 42 (2002), No. 9, Optimal design of vehicle components using to- and attainable surface finish (µm)
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mization of multiple constraint single pass 33 B. S. Yildiz, H. Lekesiz: Fatigue-based changing time (min)
face milling operations, Machining Science structural optimisation of vehicle components, V, Vhb, Vopt Cutting speed, recommended by
and Technology 5 (2001), No. 1, pp. 77-99 International Journal of Vehicle Design 73 handbook, optimum (m × min-1)
DOI:10.1081/MST-100103179 (2017), pp. 54-62 w Exponent of chip cross-sectional area
21 J. Wang: Computer-aided economic optimiza- DOI:10.1504/IJVD.2017.10003398 W Tool wear factor
tion of end-milling operations, International 34 M. Kiani, A. R. Yildiz: A comparative study of z Number of cutting teeth of the tool
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No. 3, pp. 307-320 thiness and NVH optimization, Archive and Bibliography
DOI:10.1016/S0925-5273(98)00008-5 Computational Methods Engineering 23
22 A. R. Yildiz, K. Solanki: Multi-objective optimi- (2016), pp. 723-734 DOI 10.3139/120.111024
zation of vehicle crashworthiness using a new DOI:10.1007/s11831-015-9155-y Materials Testing
particle swarm based approach, International 35 N. Pholdee, S. Bureerat, A. R. Yildiz: Hybrid 59 (2017) 5, pages 425-429
Journal of Advanced Manufacturing Technol- real-code population-based incremental learn- © Carl Hanser Verlag GmbH & Co. KG
ogy 59 (2012), No. 1-4, pp. 367-376 ing and differential evolution for many-objec- ISSN 0025-5300
DOI:10.1007/s00170-011-3496-y tive optimisation of an automotive floor-frame,
23 A. R. Yildiz, K. Saitou: Topology synthesis of International Journal of Vehicle Design 73 The authors of this contribution
multi-component structural assemblies in con- (2017), pp. 20-53
tinuum domains, Transactions of ASME, Jour- DOI:10.1504/IJVD.2017.10003397 Dr. Betül Sultan Yıldız completed her BSc and
nal of Mechanical Design 133 (2011), No. 1, 36 S. Mirjalili: Moth-flame optimization algo- MSc degrees at Uludağ University, Bursa, Turkey
011008 rithm: A novel nature-inspired heuristic para- andreceived her PhD in Mechanical Engineering
DOI:10.1115/1.4003038 digm, Knowledge-Based Systems 89 (2015), from Bursa Technical University, Turkey. Her re-
24 A. R. Yildiz: A novel particle swarm optimiza- pp. 228-249 search interests are optimal design, shape optimi-
tion approach for product design and manufac- DOI:0.1016/j.knosys.2015.07.0 zation, topology optimization, topography optimi-
59 (2017) 5
PRODUCTION-ORIENTED TESTING 429
59 (2017) 5