An intelligent system for monitoring and optimization of ball-end milling process

The paper presents an intelligent system for on-line monitoring and optimization of the cutting process on the model of the ball-end milling. An intelligent system for monitoring and optimization in ball-end milling is developed both in hardware and software. It is based on a PC, which is connected to the CNC main processor module through a serial-port so that control and communication can be realised. The monitoring system is based on LabVIEW software, the data acquisition system and the measuring devices (sensors) for the cutting force measuring. 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. Experimental results show that the proposed genetic algorithm-based procedure for solving the optimization problem is effective and efficient, and can be integrated into a real-time intelligent manufacturing system for solving complex machining optimization problems. (c) 2005 Elsevier B.V. All rights reserved.