2009 International Forum on Computer Science-Technology and Applications
Overview of the Intelligent Tools Selection in Manufacturing Process
Yulin Wang1, Jinlan Li2, Mei Zhang1, Pengfei Cui3,
1
Laboratory of Industrial Engineering, Beijing Institute of Technology, Beijng 100081, China
2
College of Mechanical and Electronic Engineering, Shandong University of Science and Technology, Tai’an 271000, China
3
Institute of Electronics, Chinese Academy of Sciences, Beijing 100190, China
yulin_wang@126.com
Abstract—Tools selection that is made artificially in
manufacturing process often takes the experts much time and
such experience is difficult to be shared. In this overview, the
general tools selection process is summarized, and the
methodologies, including based-rules method and other
preventative algorithms, are introduced according to their
applicable conditions. A practical intelligent system and a
multi-hierarchy grey selection model are given to show the
process of the intelligent tools selection and to verify its
efficiency in manufacturing production.
Keywords-intelligent tools selection; based-rules；algorithms;
expert system
I. INTRODUCTION
This Artificial tools selection in manufacturing
production often takes the experts several hours or even
days, which reduces the efficiency of production and
increases the manufacturing costs. Moreover, the experience
of selecting tools is often inherited by only several persons.
Accordingly, it is widely believed that developing an
effective system for tools selection instead of artificial efforts
is necessary for today’s manufacturing enterprises to
improve their production effects and to increase their
competition.
Researches on intelligent tools selection technology used
in manufacturing industries have emerged since 1990s and
mainly focused on the management process, based rules and
the algorithms of tools selection. Some systems have been
developed, including the tools selection management system
in Small and Medium Enterprises which is proposed by
Xuan-Linh Tran, Shraga Shoval, etc. [1], the NC cutting
tools selection system which is devised by Chuanli Li [2],
the knowledge-based methodology and tools handling by
H.L.Hausen and H.J.Neusser [3] etc.
II. TOOLS SELECTION PROCESS
It is accepted that the process of tools selection involves
significant steps as follows: to analyze production
requirements which include the production scale and the
maching technique of the parts; to establish the based-rule of
tools selection; to chose the algorithm of tools selection; to
confirm the evaluation criterions of the alternatives; to
develop the underlying database and software system and
finally to exam the practical using effects of the system.
978-0-7695-3930-0/09 $26.00 © 2009 IEEE 239
DOI 10.1109/IFCSTA.2009.179
Among these, the rules and algorithms selection are their
core. However, algorithms differ depending on the features
of the production type and parts. All these are plotted as
figure 1.
Figure 1. The Process of Tools Selection
A. Requirement Analysis
Production requirement analysis is the basis of tools
selection, which includes the production scale, the process
technique of the parts and so on. Production scales decide the
manufacturing type and the parts’ characteristics that focus
on not only the detailed but also the total attributes. Different
description types of these characteristics lead to different
divisions of the system.
In the work of A.A.Milani and Mohsen Hamedi [4], they
developed a knowledge-based system for selecting fastening
tools in automobile assembly lines. Considering a technician
would be asked the type of the task as ‘loosening’ but will
not be asked the tolerance of the fastening, the selection
speculation is rule-based.
Dissimilarly, in the research of Bo Sun, Hua Chen etc.
[5], the problems are resolved by grey relation theory and
AHP since it based on the background of networked
manufacturing. This type of questions require consideration
of many factors including processing quality, processing
time, and resources cost and manufacturing capability, thus
its solution should base on the multi-level evaluation. Since
the grey relation principle is verified to better reflect
approximate sequence of each project and the project of
maximal grey relation degree is the best one, the system
chose it as the tools selection algorithm.
B. Rule Establishment & Algorithm Selection
The based-rule relies on the analysis of the parts and
most common form is the ‘IF-THEN’ regulation. In the
study of the selection system of NC cutting tools, Chuanli Ji
[2] explained it as follows: There are some rules that
constructed and stored in the system database and once the
users input the description of the parts, the system would tackle the problems. The basic idea behind expert system is
searches for the one that mostly matches with the given fact that expertise, which is the vast body of task-specific
and takes it as the selection rule to select the optimal knowledge, is transferred from a human to a computer. This
alterative of tools. After the based-rule has been established, knowledge is then stored in the computer and the users
appropriate algorithm would be researched according to the could call upon the computer for specific advice. The
reality of the production. More detailed introduction is set computer can make inferences and arrive at a specific
forth in part Ⅲ. conclusion. Then like a human consultant, it gives advices
and explanations, and if necessary, the logic is behind the
C. Evaluation Criterions Establishment advice [6]. This general model is shown as figure 3.
The evaluation of the tools selection alternatives is
important since the selected tools should meet not only the
production techniques but also the demand of function and
manufacturing costs.
As plotted in figure 2, considering their using quality, the
tools are required to match with the machine tools which
should be flexible to adjustments and be rigid and precise.
For the consideration of time and cost, the middle pieces of
the tools should be as few as possible, which could also
improve their rigidity. Besides, sometimes the tools of the
same suppliers have priority in the alternatives.
Figure 3. The Generic Model of Expert System

Example of some general rules could be descript such as:

Rule1:
IF joint orientation IS upwards
AND IF joint position IS above the head
AND IF tool shape IS not pistol type
THEN rank = -1000.

Rule2:
IF operation type IS fastening
AND IF tool type IS straight
AND IF torque value > 100 Nm
THEN reaction bar necessity IS yes.
B. Case Study
In the study of A.A.Milani, Mohsen Hamedi [4], they
developed such a system and its whole selection processes
are as follows:
Figure 2. Machine Tools Selection Evaluation Exponent 1) A joint plotted as figure4 is demonstrated. It is a
hexagonal bolt and nut joint which is made of steel, and a
In the research of [1], evaluation criterions are divided rubber washer is also used in the joint. The torque value is
into various categories; many of them are helpful for today’s 40 Nm and the joint is above the operator’s head so the
researches. In sum, effective evaluation criterions should be
weight is a concern.
established to find a balance among the demands mentioned
above.
III. TOOLS SELECTION ALGORITHMS
Nowadays general tools selection systems could be
successfully developed on the basis of expert system without
limitation on certain unique algorithm for the problems while
the only keys are the heuristics taken from the years of
experience of the human experts and tool engineers. Figure 4. A Selected Joint

A. Rule-based Selection 2) The operator was questioned about the different

Although some general technical rules and guidelines do parameters of the joint which the system has identified to be
exist in every filed, they are rarely adequate to efficiently

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crucial in selecting the tool and finally the user preferences
regarding cost, quality and accessibility, etc.
3) After the questioning process takes about ten
minutes, the tools that their ranking numbers are higher
than a threshold set by the user are selected and
recommended by the system with their ranking numbers so
that the user could select within them.
4) As plotted in the figure5, the fifth tool in the list is an
expensive tool which is designed for another situation and
although it satisfies the geometrical and technical
requirements of the joint, it is much more expensive than the
others while it does nothing more than them in this case.
Since the task was decided to be cost effective, it has gained
a lower ranking number.
Figure 5. System User face & The Proposed Tools
The rule-based form is commonly used in tools selection
systems, which firstly calls for extraction of the maching
features to form the basis of speculation rules for the
system, which could be represented from the expert
extraction system for automatic of machining features.
C. Other Algorithms of Selection
New approaches of algorithms and their implements in
tools selection are mainly driven by the requirements for
unique manufacturing process. In 1998, E. Summad and E.
Appleton [8] considered that searching a huge explosive
decision tree is difficult to analytically solve the problem in a
practical sense, thus the Monte Carlo simulation technique
was used in their study for selecting appropriate tools in the
sheet metal parts production without any restriction on the
geometry of the features involved.
Moreover, since pocketing procedure is usually
performed by a milling operation and the boundary profile is
bounded by one or more planar profiles, Yingjie Zhang and
Yunlong Li [9] proposed a new algorithm to estimate of total
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maching time: Let Ai, vi, fi, and di be the area of the region
cut by the tool i, the optimal cutting velocity, feed-rate, and
diameter of the cutter, respectively. dmin is assumed to be the
diameter of the largest tools selected. Then the total
machining time can be estimated by equation (1):
A
Ttotal = ∑i =1 i ⋅ ξ i
M
vi ⋅ f i
1 A
=d max⋅∑i =1
M
⋅ ( i )'
vi ⋅ f i d i
Where: d max (1)
ξi ≈ ⋅
di
This is helpful to find the cutting area for a given cutter,
select the multiple tools and generate the tool path.
However, when it turns to the multi level analysis, the
grey relation method that could be used in case-selection is
studied by Bo Sun and his group [5]. They built a machine
tools multi-hierarchy grey selection model. It can be
expressed as R＝W×H, and R is comprehensive judgment
matrix for n programmed, which is known as first order
relation coefficient matrix: R= {ψ1 …, ψi, ψm}. W is weight
n
of each evaluation index, and ∑ω
k =1
k = 1 .The grey relation
matrix for each programmed is shown as equation (2) and
ζ (kj ) is relation coefficient by comparing index k of
programmed with index k of standard index set.
(2)
When hierarchy of each evaluation index is various,
multi-hierarchy grey relation selection model needs to be
applied. On the basis of monolayer grey relation selection
model, it can be expressed as C=Wi ×Ri, and C= {C1 … Ci…
Cm}. The realization method about multi-hierarchy of grey
relation selection model is shown as figure 6.
Figure 6. Multi-hierarchy Grey Relation Selection Model
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and the hierarchy relation coefficients are calculated by the Information Technology Application, 2008. IITA '08. Second
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3) In terms of final grey relation coefficient, one
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In sum, different requirements call for different selection
algorithms. IF-THEN rule is commonly used in many simple
tools selection systems while the further complex ones or the
ones have special concentrations should chose the more
unique methods to help them quickly select the tools.
IV. CONCLUSION
Artificial tools selection is a work that is based on
technicians’ experience and even perception, which urgently
needs improvement, since the traditional methods for tools
selection cost the experts lots of time and restrict the
production efficiency. The problems could be solved by
using intelligent tools selection systems which are based on
expert system, according to the production conditions such
as production scale and the parts’ characteristics, etc.
Examples including developed systems and methodologies
are discussed in this paper, which prove that such technology
is able to increase the efficiency of tools selection and to
prove the manufacturing enterprises’ production capability
today.
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