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An explicit methodology for manufacturing cost–tolerance modeling and optimization using the neural network integrated with the genetic algorithm

Published online by Cambridge University Press:  29 April 2020

A. Saravanan*
Affiliation:
Department of Production Engineering, National Institute of Technology, Tiruchirappalli 620015, India
J. Jerald
Affiliation:
Department of Production Engineering, National Institute of Technology, Tiruchirappalli 620015, India
A. Delphin Carolina Rani
Affiliation:
Department of Computer Science and Engineering, Bharathidasan University, Tiruchirappalli, India
*
Author for correspondence: A. Saravanan, E-mail: varunsarav@gmail.com
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Abstract

The objective of the paper is to develop a new method to model the manufacturing cost–tolerance and to optimize the tolerance values along with its manufacturing cost. A cost–tolerance relation has a complex nonlinear correlation among them. The property of a neural network makes it possible to model the complex correlation, and the genetic algorithm (GA) is integrated with the best neural network model to optimize the tolerance values. The proposed method used three types of neural network models (multilayer perceptron, backpropagation network, and radial basis function). These network models were developed separately for prismatic and rotational parts. For the construction of network models, part size and tolerance values were used as input neurons. The reference manufacturing cost was assigned as the output neuron. The qualitative production data set was gathered in a workshop and partitioned into three files for training, testing, and validation, respectively. The architecture of the network model was identified based on the best regression coefficient and the root-mean-square-error value. The best network model was integrated into the GA, and the role of genetic operators was also studied. Finally, two case studies from the literature were demonstrated in order to validate the proposed method. A new methodology based on the neural network model enables the design and process planning engineers to propose an intelligent decision irrespective of their experience.

Information

Type
Research Article
Copyright
Copyright © Cambridge University Press 2020
Figure 0

Fig. 1. Manufacturing cost–tolerance relationship.

Figure 1

Table 1. Various manufacturing cost–tolerance models

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Fig. 2. Proposed methodology.

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Fig. 3. Prismatic and rotational geometry nomenclature.

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Table 2. Manufacturing cost–tolerance data set

Figure 5

Fig. 4. Basic prismatic network model.

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Fig. 5. Basic rotational network model.

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Fig. 6. Best prismatic 4 × 4 × 5 × 5 × 1 BPN network model.

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Fig. 7. Best rotational BPN 3 × 3 × 3 × 1 model.

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Fig. 8. Manufacturing cost–tolerance curve for prismatic geometry.

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Fig. 9. Manufacturing cost–tolerance curve for rotational geometry.

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Table 3. Network model parameters for prismatic geometry

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Table 4. Network model parameters for rotational geometry

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Fig. 10. Gearbox assembly.

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Table 5. Input data for the gearbox assembly

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Table 6. Gearbox assembly result and comparison

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Fig. 11. Two-pin-two-hole assembly.

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Table 7. Input data for the two-pin-two-hole assembly

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Table 8. Two-pin-two-hole assembly results and comparison

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Fig. 12. Interaction effects of selection and crossover methods.

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Fig. 13. Effect of mutation and crossover rates.