SIMULATION OF END MILLING OPERATION FOR PREDICTING CUTTING FORCES TO MINIMIZE TOOL DEFLECTION BY GENETIC ALGORITHM

This paper presents a 3D simulation system which is employed in order to predict cutting forces during end milling operation. Machining errors on the machined surface mostly arise from tool deflection. Therefore, in this research an attempt is made to optimize the machining parameters with the objective of minimization of the tool deflection using Genetic Algorithm (GA). In contrast to other optimization methods, in which machining time and cost are defined as the objective functions, this algorithm considers tool deflection as the objective function, while surface roughness and tool life are the constraints. In order to verify the accuracy of the 3D simulation and the optimization process, these results are compared with experimental results obtained from the theoretical relationships. The agreement of these results with the experimental results is compared. The obtained results indicate that the optimized parameters are capable of machining the workpiece more accurately and with better surface finish.