Pergamon

Computers ind. Engng Vol. 35, Nos 3-4, pp. 571-574, 1998 1998 Published by Elsevier Science Ltd. All rights reserved Printed in Great Britain PII: S0360-8352(98)00161.2 0360-8352/98 $19.00 + 0.00

FUZZY LOGIC BASED INTELLIGENT SELECTION OF MACHINING PARAMETERS By K. Hashmi*, M.A. El Baradle** and M. Ryan* *School of Computer Applications ** School of Mechanical & Manufacturing Engineering Dublin City University ABSTRACT Fuzzy logic principles have been applied for selecting cutting conditions in machining operations. The materials data used for theoretical calculations were for medium carbon leaded steel (BHN 125-425) and Freemachining carbon wrought steel (BHN 225-425). Three different depths of cut (Imm, 4mm and 8mm) and four types of tools were used for these theoretical study, I) High Speed Steel Tool, ii) Carbide Tool-Coated, iii) Carbide Tool-Uncoated Brazed and iv) Carbide Tool-Uncoated indexable. 1998Published
by Elsevier Science Ltd. All rights reserved.

Introduction In Machinability data hand book [1], the workpiece materials are classified in various groups covering a wide range of materials according to their material hardness (BHN), ferrous, non-ferrous etc. For each work material and hardness, one may scan through different possible tool materials. For each work tool combination, based on depth of cut values, one can ascertain the type of cut (smooth or rough) and speeds and feeds are selected accordingly. These speed and feed values are usually good starting estimates. Laboratory technicians and academic researchers usually use these nominal values to conduct "bracketing tests", thus reducing the search space for parameter selection [2]. Using machining data hand book for choosing cutting conditions for material hardness that lies at the middle of the group is simple and straight forward. But there exists a degree of vagueness at the boundary cases, where two choices of cutting speeds are applicable for one choice of material hardness. In this situation, the skilled operator takes decision for using the appropriate cutting speed, based on his years of experience. However, this method of choosing data by the individual operator is not very desirable, because it may vary from operator to operator. Therefore, it is desirable to have operator independent data selection system for choosing machining operation. Different application of the fuzzy control technique use a specific shape of the fuzzy set which is dependent on the system behaviour identified by the knowledge engineers. So far there is no standard method of choosing the proper shape of the fuzzy sets of the control variables [3]. Trial and error methods are usually exercised. Table 1 summarises the recommended cutting speed ranges at three different depths of cut using four different types of cutting tool materials for tunning the particular material group Medium Carbon leaded steel (BHN 125-425) and Freemachining Carbon wrought steel (BHN 225-425). This information has been extracted from Pet'. [1]. ~'uzzv Model The input is the material hardness and the output is the cutting speed. The fuzzy sets for input fuzzy variable (HARDNESS) and output fuzzy variable (SPEED) are shown in Fig. 1.
571

572

Selected papers from the 22nd ICC&IE Conference

Ttbit Ix lht,ouamt|ed a l t b s speedr t q i 8 for Frteu~hltln I Ctrl~n Wrought Stud 0illH 115415) u d Medium Carbo8 Looded Stud 0iHiq IIS-42S) nileI four di(forenltunlq loeb
Tool Mnterbd

Depth of Cut (nun)

lrne m h l n l n $ u r b o s wrooIht llud

speedrule (=~.-'-) 1440 115-210

120-115
100-150

Media... Cnr~n leaded stem

speed ranis

xii~ spud smi

(wutol
20-55 17-43 I 1-34 160-310 105-205 14-160 87-170 67-D0 $2.|00 115-220 1.5-170

21-49 17038

Ckrbide I o ~ ,,~M**,*,4

(VlUJ)
Caddie m (kmk~k)

100-150 70-120 60-15 120-185 15-145 "~-I15

~-DO

Fuzzy

sets

Fuzzy sets i VSLOW - very slow speed SLOW - slow speed SPEED MSLOW - medium slow speed MDHI - medium high speed HI - high speed VHIGH - very high speed Fi2. 1 Inout and outnut fuzzy variables

I VS - very soft SO - soR HARDNESS " MED - medium MH - medium hard HA - hard VII. very hard

Six rules can be consU'ucted based on the knowledge extracted from the skilled machine tool and these are as follows: Rule 1: Rule 2: Rule 3: Rule 4: Rule 5: Rule 6: if material if material ifmaterial if material if material if material hardness hardness hardness hardness hardness hardness is VS (very soft), then speed is VHIGH (very high) is SO (soft), then speed is HI (higher) is MED (medium), then speed is MDHI (medium high) is MH (medium hard), then speed is MSLOW (medium slow) is HA (hard), then speed is SLOW (slow) is VA (very hard), then speed is VSLOW (very slow)

Membership functions and universe t)artitioninf The it/angular shape was employed to descn~oe the fuzzy sets. In this model the fuzzy sets overlapped the adjacent ones by $0% level. Membership function for each fuzzy sets for input fuzzy variable HARDNESS and for output fuzzy variable SPEED are shown in Fig. 2.

ii

141

M,

k w , , ,,.emsV

C~as,pd m / m ~

~ . i ,,emily v,mam

The input universe 'material hardness' should be partitioned according to the minimum and maximum values allowed to conu'ol the system. On this basis the universe of the hardness has been split in the range of (0-20), with any value above this range assumed to be infmity and a zero value implying that the material hardness is almost a minimum value. The value of 0 is assigned to "Hardness rain" and the value of 20 to "Hardness max". In a similar manner the universe of the output, speed has been partitioned according to the range of speed required i.e. (0-I0). It has been assumed that the value of 0 is assigned to "speed rain" and the value of I0 is assigned to "speed max", for any output speed range. From Fig. 2 the discrctized universe of the fuzzy variables (HARDNESS and SPEED) are derived as shown in Table 2 and Table 3 respectively.

Selected papers from the 22nd ICC&IE Conference

Tsble 2 Deseretized Universe of Hardness

573

[][]W[]mWWW[]Jmm m mgm Bg BWW mW mWIWWWRmBRmmg mWIWm WmmW[]RIBWmmmUg

8HHJBRJHHHHHHBi

Table 3 Deseretlzed Universe of Cutfln~ Sneed Fuzzy Terms vslow slow O 1 0 0 0 0

0

I -5 .5 0 0 0 0

2 0 I 0 0 0 0

3 0 ..5 .5 0 0 0

4 0 0 I 0 0 0

S 0 0 .5
J

IS 0 0 0 I 0 0

7 0 0 0 -5 -5 0

8 0 0 0 0 I 0

j St 0 0 0 0
-5

l0 i0 0 0 l0
0

nulow
m~

0 0

vhigh

.5

Fuzzy Relation The fuzzy relation is the relation between the input (HARDNESS) and the output (SPEED) of the control system. The relationship between the input and the output can be found using contesian product expressions of the two sets. R = input*output where * represents the cartesian product. In the case of rule l, the relation would be R, ffi (material hardness)vs *(speed value)vmoa which has a membership function of p.RI ffi min (p.very softmaterial, tt very high speed} From Table 2, the VS (very soft) fuzzy set is defmod as: VS(very soft)= I/0 + .75/I + .50/2+ .25/3 + 0/4 + .... 0/20 and from Table 3, the fuzzy set VHIGH (very high speed) is defined as: VHIGH (very high speed) = 0/0 + 0/1 + 0/2 + ..... 5/9 + 1/10 Rule Combination The total combination of the six relations using 'or' operator is the maximum of the membership values and can be represented in the relation p.R, which has a membership function of

OR = MAX(ORa, OR2, OR,, oR,, ors, OR,}

and is shown in Table 4. This relationis in factthe model of the action of the process panning engineer/machine tool operator. Combining thisrelationwith any value of the material hardness that lies in itsuniverse (0-20) resultsin the required average cuttingoutput for the operation. The defuzzified output which gives the average speed value can be obtained from the following formula: Average value = Ysveed value x u(s~

For a hardness universe '7', for example, the average speed result would be Speed value = .~X5+.75x6+.5x7+.25xS+.25x9 .5+.75+.5+.25+.25 = 6.56 Table 5 gives the relationbetween the hardness universe (0-20) and the average values of output speed. Sample data from the Ref. [I] has been used to demonstrate the applicationof the fuzzy logic model and the resultsof the calculationobtained for Free machining carbon wrought steelat depth of cut l m m and using four differenttypes of cutting toolsare plotted in Fig. 3.

574

Selected papers f r o m the 22nd I C C & I E Conference

310

Table/4 Membership Function for IxR

Universe I1[ C u t t J n l S a t e d

340 340

I 0

2 0

.1 0

4 0

S 0

4 0

1 0

8 0

J J

I0 I

330 300 210 340 240 _+ II

ql

0 I -2 3 U
II

0
0

O
0

0
0

0
0

0
0

0
0

O
0

.2,5
.5

.25
..5

..5
.5 .5

.75
.5 J$

0 0 0
0

0 0 0
0 0 0

0 0 0
0

0 0 0
0

0 0 0
0

0 0 .2.5
,5

0 0 ~
..5

.5 J
..5 ..5 J ..5

.TS I .75
..5 J5 0

4 $ 6 ? 8 t
|0 II 12 13 14 15

J
J .5 J$ 0

0 O
0

230 3041 IlO 140 140 120 100 80 I0 40 3O 0

I v r
I

0
0

0
0

0
0

0
0 J5 ,.5 .';$ l

..5 "5 .5
..5 .5 .5

.75
I

0
0

s .+

0
0 ' 0 0

0
0 0 0

0
0 0 0

.2~,
.5 .5 .5

.75
.5 .25 ..5

"5
.5 .25 0

0
0 0 0

0
0 0 0

0
0 0 0

oi'
l

I I 14
8

0
0 0 0

.2.5
.5 .5 ,5

.25
.5 35 I

.,5
.5 .5 .5 J .5

.75
.5 J5 0

.5
.5 .D 0

0
0 0 0

0
0 0 0

0
0 0 0

0
0 0 0

0
0 0 0

16 17 II 19

r d n . o s s

.2.5
J

.5
.5

.75
.5

0
O

0
0

0
0

0
0

O
0

0
0

0
0

.75
I

.5
.5

.2.5
0

.2.5
0

0
0

0
0

0
0

0
0

0
0

0
0

0
0

ZOO

350

~oe

3so

4o0

iso

Soo

MeterleJ herdaoee {bhs)

fl|

$ Fussy euetla! Ipeeds t o : Prse a s e h l t l a ! , u b o a wfousht steel el d.e.e t a m l o i n ! Risk speed steel t o o l ( h J e t ) , f e l k l d e t o o l - e o s l o d ( s t s ) , f s , k l d e reel.unseated bleJed{oeub)jend Ctcblde Iool-uaeeslsd Imdo|sklo{etel)

Table 5 Average Speed Value Hardness 0 2 4 6 8 10 12 14 16 18 20 Universe 1 3 5 7 9 11 13 15 17 19 Partitioning Average 9.67 8.50 8.00 7,00 6.00 5.00 4.00 3.00 2.00 1.50 0.33 Speed 9.00 8.25 7.44 6.56 $.44 4.$6 3.44 2.$6 1.75 1.00 Value

In Fig. 3 the fuzzy cutting speed values are plotted along with the upper and lower data band limits of the cutting speed obtained from Ref. [1]. As can be seen from Fig. 3 the cutting speed values lie nicely at the middle of data band, showing very good fuzzy presentation. The results presented graphically in Fig. 3 show a very good correlation between the Machining Data Handbook's recommended cutting speed values and those predicted speed values using the fuzzy logic model. The strategy and action of the skilled machine tool operator for selecting the cutting speed and depth of cut can be described by the fuzzy set theory. The relationship between a given material hardness and the cutting speed can be described and evaluated by the fuzzy relation.
References I. Metcut Research Associates Inc. Machining Data Handbook, 3rd Edition, Volumes I and 2, Cincinnati (1980) 2. R. Singh and S. Raman, Metex-an expert system for machining planning, Int. J. Prod, Res. 30, 15011516, (1992) 3. I. Kouatli and B. Jones, An improved design procedure for fuzzy control systems. Inst. J. March. Tools Manufact. 31,107-122 (1991).