Genetic algorithm based optimization and post optimality analysis of multi-pass face milling

This paper presents an optimization technique for the multi-pass face milling process. Genetic algorithm (GA) is used to obtain the optimum cutting parameters by minimizing the unit production cost for a given amount of material removal. Cutting speed, feed and depth of cut for the finish and rough passes are the cutting parameters. An equal depth of cut for roughing passes has been considered. A lookup table containing the feasible combinations of depth of cut in finish and rough passes is generated so as to reduce the number of variables by one. The resulting mixed integer nonlinear optimization problem is solved in a single step using GA. The entire technique is demonstrated in a case study. Post optimality analysis of the example problem is done to develop a strategy for optimizing without running GA again for different values of total depth of cut.