MACHINING AND OPTIMIZATION OF 3D SCULPTURED SURFACES IN BALL- END MILLING BASED ON COMBINED ARTIFICIAL INTELLIGENCE METHODS

Abstract. An intelligent machining system is applied in a high speed machining robot with on-line monitoring and optimization for ball-end milling process. Manufacturing of 3D sculptured surfaces on high speed machining robot involves a number of machining parameters and tool geometries. An intelligent machining system for on-line monitoring and optimization in ball-end milling is developed for the simulation and testing on the PC machine. It is based on a main PC computer, which is connected to the high speed machining robot main processor so that control and communication can be realized. The system collects the variables of the cutting process by means of sensors. The measured values are delivered to the computer program through the data acquisition system for data processing and analysis. The optimization technique is based on genetic algorithms for the determination of the cutting conditions in machining operations. In metal cutting processes, cutting conditions have an influence on reducing the production cost and time and deciding the quality of a final product. Simulated results show that the proposed intelligent machining system with the genetic algorithm-based procedure for optimization is effective and efficient, and can be integrated into a real-time intelligent manufacturing system for solving complex machining optimization problems