th

6 International Scientific and Expert Conference TEAM 2014

Technique, Education, Agriculture & Management
Kecskemét, November 10-11, 2014

TOOL PATH OPTIMIZATION OF DRILLING SEQUENCE

USING GENETIC ALGORITHM
Tomislav Šarić*, Danijela Pezer, Goran Šimunović and Roberto Lujić
Department of Industrial Engineering, Mechanical Engineering Faculty in Slavonski Brod, J. J. Strossmayer
University of Osijek, Croatia
* Corresponding author e-mail: tsaric@sfsb.hr

Abstract whose elements we call arcs. Distance matrix

This paper presents the approach of searching for satisfies ineguality triangle in case when
the optimal tool path during drilling. The solution is is , for all [1].
obtained using the genetic algorithm where the In the case of plane problems,
drilling sequence optimization problem is reduced
to the Travelling Salesman Problem. The genetic is the Euclidean
algorithm is used in order to minimize the path
distance.
length, i.e. to reduce the total time of the tool path.
The goal is to minimize the total path lenght
The results achieved by the criterion of minimum
tool path ultimately lead to savings of the min (1)
technological time and decrease of the total cost of
production. The solution of the problem was within the constraints:
achieved using the MATLAB software, while the
program code was designed for the selected (2)
technological task of drilling. The achieved
software solution was simulated by the EMCO (3)
WinNC program for the Sinumerik 840D Mill
control unit.

Keywords: Expression (2) ensures that each city has visited

Optimization, Genetic Algorithm (GA), Drilling,
Travelling Salesman Problem (TSP)
1. Introduction
Tool path planning, in this case in the process of
drilling, is important for the production process
because it leads to increase of productivity and
production cost savings, especially if the tool that
performs drilling operation must visit a significant
number of places. Determination of drilling
sequence is similar to the Travelling Salesman
Problem based on finding the shortest path, where
each city is visited only once and when it is known
the distance between each city. Travelling
Salesman Problem is one of the best known and
most extensively studied combinatorial
optimization problems and it is classified as NP
(nondeterministic polynomial time) - hard
problems. His mathematical model is searching for
Hamilton's cycle at least weight in a weighted
graph, and can be defined as a complete
undirected graph G = (V,E) if it is symmetric, and
directed graph G = (V,A) if it is asymmetric (edge
weight, respectively, path lenght has different
values depending on the direction of the tour). The
set represents a set whose elements
we call the vertex,
represents a set whose elements we call edges,
while represents a set
only once, and according to the second limitations,
expression (3), are not allowed subtours, i.e.,
eliminates the possibility that in the solution
appears more than one contour.
A binary representation of solutions is not suitable
for this type of problem, and the solutions are
represented vectorial or matrix. Types of the
vectorial representation are Adjacency
Representation, Ordinal Representation, and
representation in order of the tour which was used
in this work. Each tour is possible permutation of
1,2,3,…,n where n is number of cities (in this case
the number of holes), and the number of possible
tours is n!, i.e., (n-1)! for assymetric problems, or
(n-1)!/2 for symmetric problems when the starting
point of departure of the tour are known. The case
in this paper is n!/2 because it is a symmetrical
problem and starting point of drilling isn't defined.
2. Optimization methods
Today, we have developed many methods to solve
the Travelling Salesman Problem, which can be
devided into [2]:
Exact methods – find an optimal solution, but
because of its large computational complexity are
limited to minor problems and their largest
disadvantage is the long runtime.
Brute Force algorithm searches all possible
permutations and remembers the best combination

Tomislav Šarić, Danijela Pezer, Goran Šimunović and Roberto Lujić 393
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6 International Scientific and Expert Conference TEAM 2014
Technique, Education, Agriculture &Management
Kecskemét, November10-11, 2014

to allways provide an optimal final solution,
however, because of its O(n!) complexity is the
impractical even for the 10 cities.
Linear programming is the optimization method of
the linear objective function, which is subject to
constrains of linear equalities and inequalities.
Branch and Bound is the general algorithm for
searching the optimal solutions of many
optimization problems. It consist of counting all the
potential solutions, where large subsets of inferior
solutions were rejected.
There are used method of dynamic search,
Backtracking method, and Branch & Cut method.
Approximation methods – use the algorithms
that provides so-called sub-optimal solutions in a
relatively short time. The best known
approximation algorithm is the Christofides'
algorithm.
Heuristics methods – the methods for solving
problems based on experience.
Solving the Travelling Salesman Problem with the
algorithm of nearest neighbor starts searching from
arbitrary initial city, and every next city is the one
which is nearest to the current city without being
visited yet. This algorithm usually does not provide
an optimal solution, because it doesn't use all of
the available data, for example, some of the city
are visited too early which prevents later to finding
a better solution, respectively, the solution
converges to a local minimum. The adventage of
this algorithm is in its implementation speed with a
good optimum approximation, and it is used to
compare and testing the other algorithms.
Except the mentioned, there is used the Greedy
algorithm, Heuristic of nearest and farthest
insertion, and Nearest insertion of arbitrary city.
Metaheuristics methods – are iterative procedure
of solving combinatorial optimization problems that
may include traditional heuristics such as one step
of the procedure (e.g. local search). The essential
characteristic of metaheuristics is to use the
strategy of finding the global optimum. Sometimes
metaheuristics allows the acceptance of inferior
solutions of objective function in order to achieve
the escape from a local optimum.
gens
The best known examples are simulated
annealing, genetic algorithms, and ant colonies
optimization methods.
Solving the Travelling Salesman Problem with
evolutionary algorithms is very common. Although
evolutionary algorithms do not allways find an
optimal solution, their advantage is that they can in
real time find a solution that is very close to the
optimal. Solving the problem of drilling sequence
was obtained also by using GA.
3. Genetic algorithm (GA) – general model
GA is the optimization method based on the
natural evolution, with the basic idea of survival of
the best individuals in the population. Unlike most
of the deterministic algorithms, GA does not start
search from the one point of solution, already from
a hole range of potential solutions that are usually
randomlly generated and represents the inital
population of the genetic algorithm. Depending on
the given problem, capability (goodness) defined in
fitness (objective) function, are determinate to the
initial population. In every generation choosen
solution is closer to the optimum in comparison
with other members of the population, while inferior
solutions were rejected. Selected solutions are
subjected to genetic crossover and mutation
operators in order to create a new generation. The
procedure is performed iteratively until the
stopping criterion is met as a defined by the user.
The basic algorithm structure is shown in Figure 1.
Generate initial population P(t)
Evaluate population P(t)
While stopping criteria not satisfied Repeat
Select some elements from P(t) to copy into
P(t+1)
Crossover of some elements of P(t) and put
into P(t+1)
Mutation of some elements of P(t) and put into
P(t+1)
Evaluate new population P(t+1)
P(t)= P(t+1)
Figure 1. Standard genetic algorithm [3]
The basic terms used in the work of genetic
algorithm [4] are shown in the Figure 2.

genotype 0 1 0 1 1 0 1
0 0 1 1 1 0 0 1 0 1 1 1 0
fenotype 11 9 25 14
chromosome 1 chromosome 2 chromosome 3 chromosome 4
population
Figure 2. Display of the basic terms int the work of the GA

The chromosome consist of the genes, where Each chromosome represents the one individual,
each gen is an one parameter, or variable xi = (i = or a one possible solution of the problem, and the
1,…,n). set of all chromosomes makes the population, i.e.,
X = [chromosome] = [gen1,…,genn] = [x1,…,xn]. the set of all possible solutions. The genetic

394 Tool Path Optimization of Drilling Sequence using Genetic Algorithm

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6 International Scientific and Expert Conference TEAM 2014
Technique, Education, Agriculture & Management
Kecskemét, November 10-11, 2014

algorithm process consist of the next steps: Reproduction (selection)

encoding of individuals, evaluation of fitness of
individual, selection, crossover, mutation and
solution decoding.
Encoding
The choise of solutions representation has a great
importance because it can significantly affect at the
efficiency of genetic algorithm, and usually is
represented by string of bits and binary numbers.
Evaluation
Based on the defined chromosome (individual)
randomly formed initial population, i.e., pre-
selected sufficiently large number of satisfactory
solutions to the problems, and for the each solution
determines the value of the fitness function [5].
1 1 0 0 1
chromosome 1
0 1 0 1 1
chromosome 2
Figure 3. Selection in GA procedure
By the selection (Figure 3), good individuals are
chosen and it will participate in reproduction, while
inferior individuals were rejected. Selection
involves the storage and transfer of good
characteristics (genes) to the next generations of
individuals [4]. Several methods of selection are
developed and some of them will bementioned:
 Proportional selection in which individuals with
the greatest ability (goodness) have the best
chanse of being selected, and
 Tournament selection in which randomly, from
the entire population, selects a certain number
of individuals, from which choose the best for
the next generation, and the process is repeated
untill the number of offsprings reaches the
population size.
REPRODUCTION
1 1 0 0 1
(SELECTION)
parent

Crossover performance, and they are usually performed at a

Genetic crossover operator provides the change of single point (Figure 4) or two crossing point (Figure
the genetic material between individuals 5), whereby the point of crossing randomly chosen.
(chromosomes). After couples of parents were Traditional crossing operation is not applicable in
selected from population, because of selection the case of tool path optimization, because of
process, and with crossing method from them requires that each gene in the chromosome may
offsprings that inherit properties from parent are occure only once, and the ordinal sequence was
created. There are many ways of crossing used [5].
crossover point

parent 1 1 1 0 0 1 1 1 1 1 0 offspring 1
CROSSOVER
parent 2 0 1 1 1 0 0 1 0 0 1 offspring 2
parent' s chromosome offsprings
Figure 4. Crossover in one (single) point
crossover points

parent 1 1 1 0 0 1 1 1 1 1 1 offspring 1
CROSSOVER
parent 2 0 1 1 1 0 0 1 0 0 0 offspring 2
parent' s chromosome offsprings
Figure 5. Crossover in two points

Mutation Although the selection and crossover generates

Mutation is a genetic operator by which the space
of solutions are searched and exactly mutation
greatly helps to avoid local optima of the fitness
function which we optimize. Applying of mutation
the diversity of genetic material is achieved and
searching for new – potentially best solutions are
enabled (e.g. in the case that all the individuals of
the population have the same gene in a specific
location in the chromosome, only the crossing
could not change this gene).
the new strings, they do not introduce a new
information in the population on the bit level.
Therefore, a mutation is introduce, which brings
the new aspekts in the population, that can arise
the new search directions, thereby creating the
conditions to prevent retention of local extremes.
Mutation (Figure 6) at the level of genotype,
randomly entries a new genetic material in the
chromosomes or individuals [4].

Tomislav Šarić, Danijela Pezer, Goran Šimunović and Roberto Lujić 395
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6 International Scientific and Expert Conference TEAM 2014
Technique, Education, Agriculture &Management
Kecskemét, November10-11, 2014

There are different types of mutations, which operator, and it was used the permutation in which
among the other things, depends of the are two randomly selected genes swich the values
representation of chromosomes. In this paper, it is (Figure 7).
not possible to apply the traditional mutation

parent 1 1 0 0 1 MUTATION 1 1 1 0 1 offspring

random choosen gen mutate gen

Figure 6. Mutation

parent 1 1 0 0 1 PERMUTATION 1 1 0 1 0 offspring

random choosen gen

Figure 7. Permutation
Decoding
Decoding is the process of converting a binary
number to a potential solution.
Elitism
The protection of the best individual of the possible
changes or elimination, applying of genetic
operators during the evolutionary process
(selection, crossover or mutation) is called elitism.
However, although elitism can improve
performance of genetic algorithm, the protection of
the best individual of each step of evolution can
significantly slow down the genetic algorithm.
Genetic algorithm parameters
The tipically algorithm parameters are population
size, number of generations (iterations), the
crossover and mutation probability. Considering
the values of the genetic algorithm parameters, the
algorithm gives different results, faster or slower
coming to a better or inferior solutions.
The population size is parameter that directly
affects to the quality of the obtained solutions by
reducing the probability of permature convergence
to a local optimum, while the negative side of
increasing complexity of computing and thus the
total running time of the algorithm. Smaller
populations provides a better solution for a small
number of generations, and increasing of the
population is necessary to increase the number of
generations.
Number of generations is a parameter that directly
affects at the algorithm execution time, as well as
the quality of the obtained solutions. A larger
number of generations gives a better solution, but
with increasing the runing time, it is necessary to
determine a number of generations by which the
algorithm will find a satisfactory solution that may
not allways be optimal to be satisfying.
A very important role in the work of GA has a
parameter of mutation probability that allows
avoiding of “stacking“ in the local optimum at
random algorithm leaps per solutions spase.
A significant increase of the crossover probability
reduces preservation of existing solutions, i.e.,
increases the degree of destruction of individuals
with greater capability.
Termination of the algorithm
The process of creating the new generations is
repeated until a predefined stopping criterion of
evolution is not satisfied. Some of the stopping
criteria for the algorithm are reaching predefined
number of generations, satisfying the minimum
criteria or the ending of evolutionary process,
which is reflected in the way that successive
repetitions do not lead to better results.
3. Experimental part
For the selected technological task shown in
Figure 8 on the principle of Travelling Salesman,
by using genetic algorithm, sequence of drilling
was optimized. The task was defined drilling of 25
holes on the prismatic workpiece, with minimal tool
path, where the starting point of drilling depends
on the random selection of the genetic algorithm,
and after the last hole drilling the tool is necessary
return to the starting position. For a given problem
of the tool path optimization, minimizing the lenght
of tool path was realized using the MATLAB
software and the achieved software solution was
simulated in EMCO WinNC program for Sinumerik
840D Mill control unit.
The algorithm was run multiple times (50 times)
with different combinations of population size and
stopping conditions, in the aim of experimental
determination of the number of individuals in the
population and the number of generations of
genetic algorithm (for the tool path optimization
problem) an in order to determine parameters of
the algorithm that gives the best solution. Initial
population of chromosomes was randomly created,
where each chrormosome represents a string of
holes that need to drill, and each gene represents
assigned number of holes.

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6 International Scientific and Expert Conference TEAM 2014
Technique, Education, Agriculture & Management
Kecskemét, November 10-11, 2014

Figure 8. Prismatic workpiece for drilling

According to the Figure 9, there was obtained a
total distance of tool path in the amount of 318,77
mm with manual programming, while the proposed
genetic algorithm according to the size of the
population and the number of generations (which
causes stopping execution of the algorithm),
finding the optimal solution almost in the all the
combinations, i.e., the minimal distance of tool
path in the amount of 263,86 mm.
Start (final) point of tool path
Figure 9. The total distance of tool path during the
manual programming
The algorithm was tested on a sample with a small
number of holes, and the results were compared
with results obtained by heuristics nearest
neighbour method. A Genetic algorithm, for the
defined problem with 4 holes, finds an optimal
solution already for the 10 generations and 5
individuals in the population.
Table 1 shows the average values obtained for all
50 times starting of genetic algorithm, from which it
can be concluded that the genetic algorithm gives
quite stable solutions very close to the minimum.
Analyzed the data (Table 1) concluded that a
substantial increase the number of generations
and number of individuals do not give much better
solutions than the case with a smaller number of
generations and smaller number of individuals. For
a large number of individuals in the population
during performance of the algorithm there is the
possibility to appearance of a large number of
similar or identical individuals that provide good
solutions. By choosing these individuals for

Table 1. The average value of the fitness function in multiple algorithm startup
Number of Number of individuals in the population
generations 50 100 300 500 1000
100 292,7529 279,3912 269,0384 268,808 267,3062
300 270,5388 269,6934 267,3176 265,7477 264,4715
500 271,4110 270,0652 265,7013 265,6332 264,1243
1000 268,8153 266,8541 265,1995 264,6979 263,9364

reproduction, diversity of genetic material are
reduces and in that way are often obtained the
lower results for the same number of generations
with a plurality of individuals in relation to a smaller
number of individuals for the same number of
generations. For random generating a first
population, the probability of appearance a good
individual is higher when the population are larger.
Table 2 shows the average runtime of the
algorithm in seconds, depending on the number of
generations and population size. Smaller
population have a higher chanse to “stuck“ in a
local optimum, but through the generations iterates
much faster than the larger population, which is
more suitable for the complex problems, in this
case for the problem with a large number of holes.

Tomislav Šarić, Danijela Pezer, Goran Šimunović and Roberto Lujić 397
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6 International Scientific and Expert Conference TEAM 2014
Technique, Education, Agriculture &Management
Kecskemét, November10-11, 2014

The program is performed on a laptop Acer Aspire 5741G, 2.2GHz, 3 GB of RAM.

Table 2. The average time of genetic algorithm performing

Number of Number of individuals in the population
generations 50 100 300 500 1000
100 1,7599 1,7614 2,0619 2,4213 3,2463
300 4,5814 4,7976 5,8271 6,9453 9,6913
500 7,9394 8,5237 10,3454 12,2061 16,4584
1000 16,7594 17,6131 21,1964 24,7049 33,5717

To solve the problem of minimizing tool path and to
achieve the optimal solution for the proposed
genetic algorithm, it was enough 100 generations
and 100 individuals in the population.
Considering that genetic algorithm is multiple
started, which generates a new solution, some of
the obtained results have the same distance but
with another drill path. In Figure 10 is shown a
graphical representation one of possible solutions.
From Figure 11 it is evident that the value of
fitness function gradually decreases through the
generations which is an indicator of optimization
unfolding. In addition to reduce the value of the
fitness function for the best individuals, also is
reduced the mean (average) value of the fitness
function of the population.

Figure 10. Graphical display of an optimal tool path Figure 11. Fitness function depending on the
number of generations

5. Conclusion
The paper tried to find the sequence of drilling
operation that provides the shortest path, i.e.,
reduction of the total work time and efficiency
increase with the assistance of genetic algorithm.
Selection of the genetic operators and parameters
which determine behaviour of these operators is
an important for the successful algorithm work.
The algorithm in relatively short time finds the
optimal solution and therefore is reliable to use. In
order to improve finding solutions, genetic
algorithm is possible to combine with one of the
methods for searching of local optimum, which
leads to faster convergence of certain individual
according to their optimum, which is potentially the
global. This paper aims to reduce the total path,
without considering tool wear, and the problem is
solved for drilling holes of the same diametar and
depth and the further research could expand in
that sense. In further research the defined problem
could be resolved with another metaheuristic
optimization method (e.g. Particle Swarm
Optimization or Ant Colony Optimization), with the
possibility of comparing the obtained solution with
the solution achieved with CAM software.
References
[1] J. Abu Qudeiri, “Optimization of Operation
Sequence in CNC Machine Tools Using
Genetic Algorithm“, Journal of Advanced
Mechanical Design, Systems and
Manufacturing, vol.1, no.2, p. 272 – 282,
2007.
[2] V. Bosancic, A. Golemac, T. Vojkovic, “How to
Help a Traveling Salesman“, Osječki
matematički list, no.12, p.139 -149, 2012.
[3] A. Chipperfield, “Genetic Algorithm Toolbox
User's Guide, version 1.2“, [Online]. Available:
http://www.pohlheim.com/Papers/tr_gatbx12/
ChipperfieldFlemingPohlheimFonseca_tr_GA
Tbx_v12.pdf. [Accessed: 19-Jun-2014].
[4] M. Brezočnik, “Uporaba genetskega
programiranja v inteligentnih proizvodnih
sistemih“, Fakulteta za strojništvo, Maribor,
Slovenija, 2000.
[5] N. Mohamad, M.K.A. Ariffin, A. Ali,
F.Mustapha, I.M. Salleh, “Development of
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398 Tool Path Optimization of Drilling Sequence using Genetic Algorithm