Intelligent process modeling and optimization of die-sinking electric discharge machining
01 Mar 2011-Vol. 11, Iss: 2, pp 2743-2755
TL;DR: The proposed integrated (FEM-ANN-GA) approach was found efficient and robust as the suggested optimum process parameters were found to give the expected optimum performance of the EDM process.
Abstract: This paper reports an intelligent approach for process modeling and optimization of electric discharge machining (EDM). Physics based process modeling using finite element method (FEM) has been integrated with the soft computing techniques like artificial neural networks (ANN) and genetic algorithm (GA) to improve prediction accuracy of the model with less dependency on the experimental data. A two-dimensional axi-symmetric numerical (FEM) model of single spark EDM process has been developed based on more realistic assumptions such as Gaussian distribution of heat flux, time and energy dependent spark radius, etc. to predict the shape of crater, material removal rate (MRR) and tool wear rate (TWR). The model is validated using the reported analytical and experimental results. A comprehensive ANN based process model is proposed to establish relation between input process conditions (current, discharge voltage, duty cycle and discharge duration) and the process responses (crater size, MRR and TWR) .The ANN model was trained, tested and tuned by using the data generated from the numerical (FEM) model. It was found to accurately predict EDM process responses for chosen process conditions. The developed ANN process model was used in conjunction with the evolutionary non-dominated sorting genetic algorithm II (NSGA-II) to select optimal process parameters for roughing and finishing operations of EDM. Experimental studies were carried out to verify the process performance for the optimum machining conditions suggested by our approach. The proposed integrated (FEM-ANN-GA) approach was found efficient and robust as the suggested optimum process parameters were found to give the expected optimum performance of the EDM process.
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TL;DR: This paper reviews the application of non dominated sorting genetic algorithm II (NSGA-II), classified as one of MoGA techniques, for optimizing process parameters in various machining operations.
262 citations
Cites methods from "Intelligent process modeling and op..."
...[14] reported modeling process using finite element method (FEM) integrated with ANN and GA to improve in predicting the shape of crater, MRR and tool wear rate (TWR)....
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01 Jan 2016
TL;DR: This chapter describes the general knowledge of the teacher-student relationships and the fundamentals and performance of TLBO algorithm, an interesting algorithm which is inspired by the teaching and learning behaviour.
Abstract: This chapter introduces teaching-learning-based optimization (TLBO) algorithm and its elitist and non-dominated sorting multiobjective versions. Two examples of unconstrained and constrained benchmark functions and an example of a multiobjective constrained problem are presented to demonstrate the procedural steps of the algorithm.
181 citations
TL;DR: Thorough literature review of various modern machining processes is presented and may become the ready information at one place and it may be very useful to the subsequent researchers to decide their direction of research.
Abstract: Thorough literature review of various modern machining processes is presented in this paper. The main focus is kept on the optimization aspects of various parameters of the modern machining processes and hence only such research works are included in this work in which the use of advanced optimization techniques were involved. The review period considered is from the year 2006 to 2012. Various modern machining processes considered in this work are electric discharge machining, abrasive jet machining, ultrasonic machining, electrochemical machining, laser beam machining, micro-machining, nano-finishing and various hybrid and modified versions of these processes. The review work on such a large scale was not attempted earlier by considering many processes at a time, and hence, this review work may become the ready information at one place and it may be very useful to the subsequent researchers to decide their direction of research.
139 citations
TL;DR: In this paper, the ABAQUS code finite element software has been used to simulate the temperature distribution on the surface of workpiece and tool during a single discharge in the electrical discharge machining process.
Abstract: In the present study, the temperature distribution on the surface of workpiece and tool during a single discharge in the electrical discharge machining process has been simulated using ABAQUS code finite element software. The temperature dependency of material properties and the expanding of plasma channel radius with time have been employed in the simulation stage. The profile of temperature distribution has been utilized to calculate the dimensions of discharge crater. Based on the results of FEM and the experimental observations, a numerical analysis has been developed assessing the contribution of input-parameters on the efficiency of plasma channel in removing the molten material from molten puddles on the surfaces of workpiece and tool at the end of each discharge. The results show that the increase in the pulse current and pulse on-time have converse effects on the plasma flushing efficiency, as it increases by the prior one and decreases by the latter one. Later, the introduced formulas for plasma flushing efficiency based on regression model were utilized to predict the cardinal parameter of recast layer thickness on the electrodes which demands expensive empirical tests to be obtained.
122 citations
Cites background or methods from "Intelligent process modeling and op..."
...Joshi and Pande [9] introduced an intelligent process modeling and optimization of EDM process....
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...(7)) introduced by Joshi and Pande [9] the cavity volume is calculated....
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TL;DR: A comprehensive review of various approaches of material behavior modeling has been presented in this article, where different material models are compared with respect to their suitability for the design of process, tooling and product.
96 citations
References
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TL;DR: This paper suggests a non-dominated sorting-based MOEA, called NSGA-II (Non-dominated Sorting Genetic Algorithm II), which alleviates all of the above three difficulties, and modify the definition of dominance in order to solve constrained multi-objective problems efficiently.
Abstract: Multi-objective evolutionary algorithms (MOEAs) that use non-dominated sorting and sharing have been criticized mainly for: (1) their O(MN/sup 3/) computational complexity (where M is the number of objectives and N is the population size); (2) their non-elitism approach; and (3) the need to specify a sharing parameter. In this paper, we suggest a non-dominated sorting-based MOEA, called NSGA-II (Non-dominated Sorting Genetic Algorithm II), which alleviates all of the above three difficulties. Specifically, a fast non-dominated sorting approach with O(MN/sup 2/) computational complexity is presented. Also, a selection operator is presented that creates a mating pool by combining the parent and offspring populations and selecting the best N solutions (with respect to fitness and spread). Simulation results on difficult test problems show that NSGA-II is able, for most problems, to find a much better spread of solutions and better convergence near the true Pareto-optimal front compared to the Pareto-archived evolution strategy and the strength-Pareto evolutionary algorithm - two other elitist MOEAs that pay special attention to creating a diverse Pareto-optimal front. Moreover, we modify the definition of dominance in order to solve constrained multi-objective problems efficiently. Simulation results of the constrained NSGA-II on a number of test problems, including a five-objective, seven-constraint nonlinear problem, are compared with another constrained multi-objective optimizer, and the much better performance of NSGA-II is observed.
37,111 citations
TL;DR: Goldberg's notion of nondominated sorting in GAs along with a niche and speciation method to find multiple Pareto-optimal points simultaneously are investigated and suggested to be extended to higher dimensional and more difficult multiobjective problems.
Abstract: In trying to solve multiobjective optimization problems, many traditional methods scalarize the objective vector into a single objective. In those cases, the obtained solution is highly sensitive to the weight vector used in the scalarization process and demands that the user have knowledge about the underlying problem. Moreover, in solving multiobjective problems, designers may be interested in a set of Pareto-optimal points, instead of a single point. Since genetic algorithms (GAs) work with a population of points, it seems natural to use GAs in multiobjective optimization problems to capture a number of solutions simultaneously. Although a vector evaluated GA (VEGA) has been implemented by Schaffer and has been tried to solve a number of multiobjective problems, the algorithm seems to have bias toward some regions. In this paper, we investigate Goldberg's notion of nondominated sorting in GAs along with a niche and speciation method to find multiple Pareto-optimal points simultaneously. The proof-of-principle results obtained on three problems used by Schaffer and others suggest that the proposed method can be extended to higher dimensional and more difficult multiobjective problems. A number of suggestions for extension and application of the algorithm are also discussed.
6,411 citations
18 Sep 2000
TL;DR: Simulation results on five difficult test problems show that the proposed NSGA-II, in most problems, is able to find much better spread of solutions and better convergence near the true Pareto-optimal front compared to PAES and SPEA--two other elitist multi-objective EAs which pay special attention towards creating a diverse Paretimal front.
Abstract: Multi-objective evolutionary algorithms which use non-dominated sorting and sharing have been mainly criticized for their (i) O(MN3) computational complexity (where M is the number of objectives and N is the population size), (ii) non-elitism approach, and (iii) the need for specifying a sharing parameter. In this paper, we suggest a non-dominated sorting based multi-objective evolutionary algorithm (we called it the Non-dominated Sorting GA-II or NSGA-II) which alleviates all the above three difficulties. Specifically, a fast non-dominated sorting approach with O(MN2) computational complexity is presented. Second, a selection operator is presented which creates a mating pool by combining the parent and child populations and selecting the best (with respect to fitness and spread) N solutions. Simulation results on five difficult test problems show that the proposed NSGA-II, in most problems, is able to find much better spread of solutions and better convergence near the true Pareto-optimal front compared to PAES and SPEA--two other elitist multi-objective EAs which pay special attention towards creating a diverse Pareto-optimal front. Because of NSGA-II's low computational requirements, elitist approach, and parameter-less sharing approach, NSGA-II should find increasing applications in the years to come.
4,878 citations
TL;DR: Experiments show that SCG is considerably faster than BP, CGL, and BFGS, and avoids a time consuming line search.
3,882 citations
TL;DR: The authors propose an alternative learning procedure based on the orthogonal least-squares method, which provides a simple and efficient means for fitting radial basis function networks.
Abstract: The radial basis function network offers a viable alternative to the two-layer neural network in many applications of signal processing. A common learning algorithm for radial basis function networks is based on first choosing randomly some data points as radial basis function centers and then using singular-value decomposition to solve for the weights of the network. Such a procedure has several drawbacks, and, in particular, an arbitrary selection of centers is clearly unsatisfactory. The authors propose an alternative learning procedure based on the orthogonal least-squares method. The procedure chooses radial basis function centers one by one in a rational way until an adequate network has been constructed. In the algorithm, each selected center maximizes the increment to the explained variance or energy of the desired output and does not suffer numerical ill-conditioning problems. The orthogonal least-squares learning strategy provides a simple and efficient means for fitting radial basis function networks. This is illustrated using examples taken from two different signal processing applications. >
3,414 citations