Journal of Materials Processing Technology 74 (1998) 149 157

Modeling and optimization of drilling process

B.Y. Lee a,*, H.S. Liu a, Y.S. Tarng b
a b

Department of Mechanical Manufacture Engineering, National Huwei Institute of Technology, Huwei 632, Taiwan, ROC Department of Mechanical Engineering, National Taiwan Uni6ersity of Science and Technology, Taipei 106, Taiwan, ROC Received 22 October 1996

Abstract In this paper, the use of an abductive network for modeling drilling processes is rst described. The abductive network is composed of a number of functional nodes, these nodes being self-organized to form an optimal network architecture by using a predicted squared error (PSE) criterion. Once the process parameters (drill diameter, cutting speed and feedrate) are given, the drilling performance (tool life, metal removal rate, thrust force and torque) can be predicted by this developed network. A simulated annealing optimization algorithm with a performance index is then applied to the developed network when searching for the optimal process parameters. Experimental results are provided to conrm the effectiveness of this approach. 1998 Elsevier Science S.A.
Keywords: Abductive network; Drilling processes; Drilling performance

1. Introduction The largest amount of money spent on any one class of cutting tools is spent on drills. Therefore, from the viewpoint of cost and productivity, modeling and optimization of drilling processes are extremely important for the manufacturing industry [1]. In this paper, an abductive network [2] is used to model drilling processes from nite drilling data and then a simulated annealing optimization technique [3] is applied to this network for obtaining the optimal drilling process parameters. Abductive networks based on the abductive modeling technique are able to represent complex and uncertain relationships between input and output variables [2]. Basically, abductive networks are composed of a number of polynomial functional nodes and are organized into several layers. The best network structure, number of layers and functional node types can be determined automatically by using a predicted squared error (PSE) criterion [4]. In other words, unlike most approaches to regression and neural networks, the abductive modeling technique can automatically synthesize the optimal net* Corresponding author. Fax: + 886 2 7376460; e-mail: ystarng@mail.ntust.edu.tw 0924-0136/98/$19.00 1998 Elsevier Science S.A. All rights reserved. PII S 0 9 2 4 - 0 1 3 6 ( 9 7 ) 0 0 2 6 3 - X

work architecture instead of requiring the user to specify the network architecture in advance. In addition, the iterative tuning process necessary with regression or neural network approaches is largely reduced in the abductive approach. It has also been shown that the prediction accuracy in abductive networks is much greater than that in neural networks [2]. In this paper, it is shown that the tool life, metal removal rate, thrust force and torque under varying drill diameter, cutting speed and feedrate can be predicted reasonably by means of the developed network. Once the drilling process model is constructed by the abductive network an appropriate optimization algorithm with a performance index is then employed to search for the optimal drilling parameters. In this paper, a sound optimization method of simulated annealing [5] is adopted. Traditionally, the annealing process, used in metal working, involves heating the metal to a high temperature and then letting it cool down gradually to reach a minimum energy state. The simulated annealing algorithm is a simulation of the annealing process for minimizing the performance index. It has been shown that simulated annealing can provide an effective way to jump out from a local optimum and draw a near-global optimum [6]. As a result, the simulated annealing algorithm has emerged as a general tool

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for optimization of arbitrary functions and has been applied successfully in noise ltering in image processing [7]. VLSI layout generation [8], discrete tolerance design [9], cutting parameter selection in wire electrical discharge machining [10], etc. Firstly, the theory of abductive networks is introduced. The experimental details of using an abductive network in modeling the drilling process are then described. The theory of simulated annealing is briey introduced and then applied to searching for the optimal process parameters in drilling. Finally, the paper concludes with a summary of the study.

normalized input, the corresponding polynomial function being expressed as: y1 = w0 + w1x1 (1)

where x1 is the original input, y1 is the normalized input and w0 and w1 are the coefcients of the normalizer. During this normalization process, the normalized input y1 is adjusted to have a mean of zero and a variance of unity.

2. Description of abductive networks It is well known that reasoning from general principles and initial facts to new facts with certainty is called deductive reasoning. However, reasoning in real problems is very often uncertain. Therefore, another class of reasoning, called abductive reasoning, is dened as reasoning from general principles and initial facts to new facts under uncertainty [11]. An abductive network is a network for modeling numerical information through abductive reasoning. As a result, the abductive network can be used effectively as a predictor for estimating the outputs of complex systems, as a classier for handling difcult pattern recognition problems, or as a system identier for determining which inputs are important to the modeling system, etc. In an abductive network, complex systems are decomposed into smaller, simpler sub-systems and grouped into several layers using polynomial functional nodes. At the same time, inputs are also sub-divided into groups, then transmitted into individual functional nodes. These nodes evaluate the limited number of inputs by a polynomial function and generate an output to serve as an input to the subsequent nodes of the next layer. The general methodology of dealing with a limited number of inputs at a time, then summarizing the input information and then passing the summarized information to a higher reasoning level, is related directly to human behavior, as observed by Miller [12]. Therefore, abductive networks can be recognized as a special class of biologically-inspired networks with machine intelligence [13].

2.1.2. Unitizer On the other hand, a unitizer converts the output of the network to the real output. The polynomial equation of the unitizer can be expressed as:
y1 = w0 + w1x1 (2)

where x1 is the output of the network, y1 is the real output and w0 and w1 are the coefcients of the uni-

2.1. Polynomial functional nodes

In the present study, several types of polynomial functional nodes (Fig. 1) are used to model drilling processes in the abductive network. An explanation of these polynomial functional nodes is given as follows.

2.1.1. Normalizer A normalizer transforms the original input into the

Fig. 1. Various polynomial functional nodes.

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tizer. The mean and variance of the real output must be equal to those of the output used to synthesize the network.

2.1.3. Single node The single node only has one input and its polynomial equation is limited to the third degree, i.e.:
y1 = w0 + w1x1 +w2x +w3x
2 1 3 1

rst. Then, a predicted square error (PSE) criterion is used to automatically determine an optimal network structure [4]. The principle of the PSE criterion is to select as accurate, but less complex, a network as possible. To accomplish this, the PSE is composed of two terms, i.e.: PSE=FSE+ KP (7)

(3)

where x1 is the input to the node, y1 is the output of the node and w0, w1, w2 and w3 are the coefcients of the single node.

where FSE is the average square error of the network for tting the training data and KP is the complex penalty of the network, expressed by the following equation: KP= CPM 2| 2 K P N (8)

2.1.4. Double node The double node takes two inputs at a time and its third-degree polynomial equation has the cross-term so that the interaction between the two inputs can be considered, i.e.:
y1 = w0 + w1x1 +w2x2 +w3x 2 +w4x 2 +w5x1x2 +w6x 3 1 2 1 +w7x 3 2 (4)

where x1, x2 are the inputs to the node, y1 is the output of the node and w0, w1, w2, , w7 are the coefcients of the double node.

2.1.5. Triple node Similar to the single and double nodes, the triple node with three inputs has a more complicated polynomial equation allowing interaction amongst these inputs, i.e.:
y1 = w0 + w1x1 +w2x2 +w3x3 +w4x 2 +w5x 2 +w6x 2 1 2 3 +w7x1x2 + w8x1x3 +w9x2x3 +w10x1x2x3 +w11x 3 1 +w12x 3 +w13x 3 2 3 (5)

where CPM is the complex penalty multiplier, K is the number of coefcients in the network, N is the number of training data and | 2 is a prior estimate of the model P error variance. As illustrated in Eq. (7), the tting accuracy increases with decreasing FSE. Usually, a more complex network has a better tting accuracy corresponding to a smaller value of FSE. On the other hand, the more complex the network, the larger will be the value of KP (Eq. (8)). Hence, the PSE criterion performs a trade-off between model accuracy and complexity. In the network synthesis and evaluation, the optimal abductive network is the network with the minimum value of PSE. In addition, CPM (Eq. (8)) can be used to adjust the trade-off between model accuracy and complexity. A complex network will be penalized more in the PSE criterion as the CPM is increased. Contrarily, a complex network will be selected if the CPM is decreased. To let the network have a better accuracy, CPM is selected as 0.1 in the following network synthesis.

where x1, x2, x3 are the inputs to the node, y1 is the output of the node and w0, w1, w2, , w13 are the coefcients of the triple node.

3. Modeling of drilling processes As mentioned earlier, a training data-base with regard to process parameters and drill performance is required in order to be able to build an abductive network for the modeling of drilling processes. In the experiments, a number of drilling experiments were carried out on a CNC machining center (First MCV641) using HSS twist drills for the machining of S45C steel plates. The drilling process parameters were selected by varying the drill diameter D in the range of 812 mm, the cutting speed U in the range of 1030 m min 1 and the feedrate f in the range of 0.060.24 mm rev 1. Each of these process parameters was set at three levels (Table 1). Therefore, 27 (3 3 3) drilling experiments were designed based on the process parameter combinations. However, only 25 drilling experiments were performed due to the limited power of the machine. The drill-life is dened as the period of

2.1.6. White node The white node is used to summarize all linear weighted inputs plus a constant, i.e.:
y1 = w0 + w1x1 +w2x2 +w3x3 ++ wnxn (6)

where x1, x2, x3, , xn are the inputs to the node, y1 is the output of the node and w0, w1, w2, , wn are the coefcients of the triple node. Now that the functions of polynomial functional nodes are explained, the next step is to construct an abductive network based on these functional nodes.

2.2. Network synthesis and e6aluation

To build an abductive network, a training data-base with the information of inputs and outputs is required

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Table 1 Experimental process parameters and drilling performance Test number D (mm) V (m min1) f (mm rev1) Tool life (s) Metal removal rate (mm3 min1) 1200 2999 2399 5999 9598 3599 8998 14 397 1502 3756 6010 3005 7512 12 020 4507 11 269 18 030 1797 4493 3595 8987 14 379 5399 13 496 21 595 Thrust force (N) Torque (N cm)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

8 8 8 8 8 8 8 8 10 10 10 10 10 10 10 10 10 12 12 12 12 12 12 12 12

10 10 20 20 20 30 30 30 10 10 10 20 20 20 30 30 30 10 10 20 20 20 30 30 30

0.06 0.15 0.06 0.15 0.24 0.06 0.15 0.24 0.06 0.15 0.24 0.06 0.15 0.24 0.06 0.15 0.24 0.06 0.15 0.06 0.15 0.24 0.06 0.15 0.24

528 30 226 45 38 176 40 31 940 527 60 282 75 59 188 63 39 340 136 283 68 43 170 60 38

98 128 87 153 225 88 145 216 116 206 279 117 203 266 124 181 272 175 237 152 229 334 148 234 313

223 407 175 359 576 178 378 546 298 663 957 288 619 870 271 538 813 424 842 400 803 1139 371 746 1087

drilling time until the average ank wear land VB is equal to 0.3 mm or the maximum ank wear land VBmax is equal to 0.6 mm, this tool-life criterion being recommended by the International Standards Organization (ISO). In the experiments, the ank wear land was measured on both cutting edges of the drill using a tool microscope (Isoma). The mean ank wear land VB was calculated by averaging six places of the ank wear land on the cutting edges (Fig. 2). The metal removal rate (MRR) is calculated by using the following equation: MRR= yD 2 fN 4 (9)

sponding process parameters (drill diameter, cutting speed and feedrate) is summarized and listed in Table 1. Based on the developed training data-base, a threelayer abductive network for predicting tool life is synthesized automatically (Fig. 3). Similarly, Fig. 4 shows

where D is the drill diameter (mm), f is the feedrate (mm rev 1) and N is the rotational speed of the drill (rpm), which can be calculated from the equation: N= 1000U yD (10)

where U is the cutting speed (m min 1). The thrust force and torque signals were measured using a dynamometer (Kistler 9271A) under the workpiece. When the drill fully entered the workpiece, the steady-state portions of the thrust force and torque signals were obtained and used as the inputs to the network. The drilling performance (tool life, metal removal rate, thrust force and torque) with the corre-

Fig. 2. Features of the ank wear land on the drill.

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Fig. 3. Abductive networks for predicting drill-life.

the developed abductive networks for predicting thrust force and torque. All of the polynomial equations used in these networks (Figs. 3 and 4) are listed in the Appendix A.

4. Simulated annealing algorithm In condensed-matter physics, annealing is referred to as a physical process that is used to reconstruct the crystal structure of a solid with a low energy state. A solid in a heat bath is rst heated to a temperature above the melting point of the solid; at this temperature, all of the particles of the solid being in a violent random motion. The temperature of the heat bath is then reduced slowly, all particles of the solid re-arranging themselves and tending towards a low energy state. As the cooling of the particle is carried out sufciently slowly, lower and lower energy states are obtained, until the lowest energy state is reached. In 1953, Metropolis proposed a criterion to be used to simulate the cooling of a solid for reaching a new energy state [14]. Based on the Metropolis criterion, an optimization algorithm called simulated annealing was developed by Kirkpatrick [5]. It has been shown that the simulated annealing algorithm possesses several ad-

vantages in comparison with traditional optimization algorithms. First, the simulated annealing algorithm does not need the calculation of the gradient descent that is required for most traditional optimization algorithms, which means that the simulated annealing algorithm can be applied to all kinds of objective and constraint functions. Next, the simulated annealing algorithm with probabilistic hill-climbing characteristics can nd the global minimum efciently, instead of the objective function being trapped in a local minimum, with surrounding barriers. Furthermore, the simulated annealing search is independent of the initial conditions. In this paper, the simulated annealing algorithm is used to search for the optimal process parameters, Fig. 5 showing the ow chart in the simulated annealing searching. First, an initial temperature TS, a nal temperature Te and a set of initial process parameter vector ( X0 is given. The objective function obj is dened based on the drilling performance index: this will be discussed in Section 5. A small randomly generated perturbation is applied to the process parameters. The objective function obj is recalculated using the perturbed compensation parameters. If the new objective function becomes smaller, the perturbed process parameters are accepted as the new process parameters and the temperature T drops a little, i.e.:

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Fig. 4. Abductive network for predicting thrust force and torque.

Ti + 1 =Ti CT

(11)

where CT is the decaying ratio for the temperature (CT B 1) and i is the index for the temperature decrement. However, if the objective function becomes larger, the probability of the acceptance of the perturbed process parameters is given based on the Metropolis criterion, i.e.: Pr(obj)=exp

Dobj kBT

(12)

ity are the criteria for the determination of drilling performance. Therefore, the maximum tool life and the maximum metal removal rate should be considered for optimizing drilling performance. Since the tool life and the metal removal rate are the two different objectives, a normalization of tool life and metal removal rate between zero and unity is required. A weighting method is then adopted to transform the normalized tool life TL and normalized metal removal rate MR into a single objective format. The objective function obj is formulated as follows: obj= w1TL w2MR (13)

where kB is the Boltzmann constant and Dobj is the difference in the objective function. The above procedure is repeated until the nal temperature Te is reached and then the optimal process parameters with the minimum objective function are outputted.

where w1 and w2 are the weights of the normalized tool life TL and normalized metal removal rate MR in optimization. At the same time, the thrust force FT and torque TQ should be kept at an acceptable level. The inequality constraints on the thrust force FT and torque TQ are given as follows: 0B FT B UFT 0 B TQ B UTQ (14) (15)

5. Optimization of drilling processes Once the drilling process model has been developed, the use of this model to optimize the drilling processes and then to obtain the optimal process parameters will be demonstrated in this section. To determine the optimal process parameters, the objective function has to be dened rst. As mentioned earlier, cost and productiv-

where UFT and UTQ are the upper bounds of the thrust force FT and of the torque TQ, respectively. Several cases are presented to illustrate the optimization of the process parameters in drilling operations. In

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Fig. 5. Flow chart for the simulated annealing searching.

these cases, the parameters used in the simulated annealing algorithm are given as follows: the initial temperature TS = 100C, the nal temperature Te = 0.0001C, the decaying ratio CT =0.95, the Boltzmann constant kB =0.00667, the upper bound of the

thrust force UFT = 300 N and the upper bound of the torque UTQ = 1000 N cm. In addition, drill diameters of D= 9 and 11 mm, different from those in the training data-base (Table 1), are selected in these cases to verify how well the abductive network performs. Through the simulated annealing searching, the optimal process parameters with several weighting combinations are obtained (Table 2). To save the tool cost in drilling, the process parameters with a longer tool life can be obtained by increasing the weight of w1. For example, w1 = 1.0 and w2 = 0.0 are selected in cases 1 and 2 (Table 2). A cutting speed of 10 m min 1 and a feedrate of 0.08 mm rev 1 are recommended to obtain the longest drill-life in the optimization procedure. A comparison of the predicted and observed ank wear at the end of the drill-life is also presented in Table 2. It can be seen that the developed network can predict the drill-life very well. To further understand the tool-life curve, the effect of drilling time on ank wear in this drilling test is shown in Fig. 6. It can be seen that the tool-life curve consists of three stages with different wear rates. First, there is a high wear rate in the initial stage of drilling. After the occurrence of the initial wear, a progressive ank wear characterized by a nearly steady wear rate is found in the second stage. Finally, a rapid wear rate is presented in the third stage until catastrophic failure of the drill. It can be seen that the predicted tool life of 861 s is very close to the zone of the end of the progressive wear (Fig. 6). Therefore, the drill should be replaced when the period of drilling time reaches the predicted tool life, otherwise a rapid deterioration of the drill may occur if the drill is still in use. A photograph of the drill at the end of the predicted drill-life is shown in Fig. 7. On the other hand, as the weight of w2 increases, the process parameters with a higher metal removal rate can be obtained so as to improve the productivity of drilling operations. However, as shown in cases 3 and 4 (Table 2), the tool life decreases with increase of the metal removal rate. Therefore, the values of w1 and w2 can be used to adjust the trade-off between tool cost and productivity in optimization. For instance, cases 5 and 6 are the drilling tests with consideration of the

Table 2 Experimental verication of the modeling and optimization of drilling processes Test number D (mm) V (m min1) f (mm rev1) w1 w2 Predicted tool life (s) Tool wear (mm) Prediction 1 2 3 4 5 6 11 9 11 9 11 9 10.00 10.00 30.00 30.00 11.74 10.97 0.08 0.08 0.24 0.24 0.08 0.08 1.00 1.00 0.00 0.00 1.00 0.80 0.00 0.00 1.00 1.00 0.80 1.00 861 938 38 37 660 803 0.300 0.300 0.300 0.300 0.300 0.300 Experiment 0.297 0.294 0.322 0.309 0.329 0.304 1.00 2.00 +7.33 +3.00 +9.67 +1.33 Error (%)

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Fig. 6. Effect of drilling time on ank wear (D=11 mm; V =10 m min 1; f =0.08 mm rev 1).

trade-off between tool cost and productivity, for which it can be found that the prediction error of the tool life for each case (Table 2) is less than 10%. In the foregoing discussion, it has been clearly shown that the process parameters with an optimum drilling performance can be obtained systematically through this approach.

6. Conclusions In this paper, self-organized abductive networks to model drilling operations have been reported. The rela-

tionships between process parameters and drilling performance can be constructed by the abductive networks. A global optimization algorithm, simulated annealing, is then applied to these networks for searching for optimal drilling process parameters subject to an adjustable objective function and inequality constraints. Several drilling tests using the optimal process parameters were performed to conrm the effectiveness of this approach. As a result, a useful technique for the modeling and optimization of drilling processes has been demonstrated in this study. Acknowledgements This research was partially supported by the National Science Council of the Republic of China under grant number NSC85-2216-E011-023. Appendix A (A) Normalizer 1. Z01 = 6.12+ 0.612D 2. Z02 = 2.56+ 0.123V 3. Z03 = 1.95+ 13.68f (B) Unitizer 1. Tool Life=179.36+215.28X31 2. Thrust Force= 189.08+70.59Y31 3. Torque=558.88+ 283.55Z21 (C) Single node 1. Y11 = 0.109+0.0596Z02 0.114Z 2 02 (D) Double node 1. X12 = 0.5030.391Z02 0.577Z03 + 0.223Z 2 02 + 0.261Z 2 + 0.291Z02Z03 03 2. X13 = 0.0340.446Z02 0.268Z 2 + 0.304Z 2 01 02 + 0.0317Z01Z02

Fig. 7. Photograph of the drill at the end of the predicted drill life (drilling conditions as shown in Fig. 6).

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3. Z11 = 0.114Z02 +0.835Z03 +0.027Z 2 02 0.0217Z 2 0.054Z02Z03 03 4. Z21 =Z11 + 0.55Z01 +0.26Z11Z01 (E) Triple node 1. X11 = 0.087+0.032Z01 0.364Z02 0.603Z03 0.38Z 2 + 0.193Z 2 +0.231Z 2 01 02 03 + 0.07Z01Z03 +0.336Z02Z03 0.107Z01Z02Z03 2. X21 = 0.058+0.918X11 +0.477X12 0.264X13 1.22X 2 0.699X 2 0.468X 2 11 12 13 + 2.02X11X12 +2.74X11X13 1.831X12X13 + 1.06X11X12X13 0.363X 3 0.419X 3 11 12 + 0.404X 3 13 3. X31 = 0.135+0.769X21 0.076Z02 0.125Z03 + 0.0394X 2 0.167X21Z02 0.158X21Z03 21 0.108Z02Z03 0.0979X21Z02Z03 0.012X 3 21 4. Y21 = 0.13+0.256Y11 +0.502Z01 +0.85Z03 + 5.44Y 2 + 0.0618Z 2 0.464Y11Z01 11 03 + 0.199Y11Z03 +0.1Z01Z03 5. Y31 = 0.0171.38Y21 +2.27Y12 +0.0828Z01 14.3Y 2 13.7Y 2 +0.0131Z 2 +28Y21Y12 21 12 01 + 0.262Y21Z01 0.275Y12Z01 0.148Y21Y12Z01 +0.628Y 3 0.513Y 3 21 12 (F) White node 1. Y12 =0.493Z01 0.042Z02 +0.862Z03

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