The Optimization of Machining Parameters for Milling Operations by Using the Nelder–Mead Simplex Method

Abstract

The purpose of machining operations is to make specific shapes or surface characteristics for a product. Conditions for machining operations were traditionally selected based on geometry and surface finish requirements. However, nowadays, many researchers are optimizing machining parameters since high-quality products can be produced using more expensive and advanced machines and tools. There are a few methods to optimize the machining process, such as minimizing unit production time or cost or maximizing profit. This research focused on maximizing the profit of computer numerical control (CNC) milling operations by optimizing machining parameters. Cutting speeds and feed are considered as the main process variables to maximize the profit of CNC milling operations as they have the greatest effect on machining operation. In this research, the Nelder–Mead simplex method was used to maximize the profit of CNC milling processes by optimizing machining parameters. The Nelder–Mead simplex method was used to calculate best, worst, and second-worst value based on an initial guess. The possible range of machining parameters was limited by several constraints. The Nelder–Mead simplex method yielded a profit of 3.45 ($/min) when applied to a commonly used case study model.