Fuzzy Logic For Modeling Machining Process

Artif Intell Rev
DOI 10.1007/s10462-012-9381-8
Fuzzy logic for modeling machining process: a review
M. R. H. Mohd Adnan · Arezoo Sarkheyli ·

Azlan Mohd Zain · Habibollah Haron
© Springer Science+Business Media Dordrecht 2013
Abstract The application of artificial intelligence (AI) techniques in modeling of machin-

ing process has been investigated by many researchers. Fuzzy logic (FL) as a well-known
AI technique is effectively used in modeling of machining processes such as to predict the
surface roughness and to control the cutting force in various machining processes. This
paper is started with the introduction to definition of FL and machining process, and their
relation. This paper then presents five types of analysis conducted on FL techniques used
in machining process. FL was considered for prediction, selection, monitoring, control and
optimization of machining process. Literature showed that milling contributed the highest
number of machining operation that was modeled using FL. In terms of machining perfor-
mance, surface roughness was mostly studied with FL model. In terms of fuzzy components,
center of gravity method was mostly used to perform defuzzification, and triangular was
mostly considered to perform membership function. The reviews extend the analysis on the
abilities, limitations and effectual modifications of FL in modeling based on the comments
from previous works that conduct experiment using FL in the modeling and review by few
authors. The analysis leads the author to conclude that FL is the most popular AI techniques
used in modeling of machining process.
Keywords Artificial intelligence · Fuzzy logic · Machining process · Machining parameter
M. R. H. Mohd Adnan (B) · A. Sarkheyli · A. Mohd Zain · H. Haron

Soft Computing Research Group, Faculty of Computing,
Universiti Teknologi Malaysia, 81310 UTM Skudai, Johor, Malaysia
e-mail: aban.ridhwan.adnan@gmail.com
A. Sarkheyli
e-mail: arezo.sarkheyli@gmail.com
A. Mohd Zain
e-mail: azlanmz@utm.my
H. Haron
e-mail: habib@utm.my
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M. R. H. Mohd Adnan et al.
1 Introduction
Artificial Intelligence (AI) is the science and engineering of making intelligent machines,
especially intelligent computer programs. It is related to the similar task of using computers
to understand human intelligence, but AI does not have to confine itself to methods that are
biologically observable. AI has produced a number of powerful tools, which are practical
use in engineering to solve difficult problems normally requiring human intelligence. AI
consists of many branches viz., expert system (ES), Genetic algorithm (GA), fuzzy logic
(FL), artificial neural network (ANN), Simulated Annealing (SA), Ant colony optimization
(ACO), Particle swarm optimization (PSO) and various swarm intelligence. The predictions
resulted from the AI-based approaches are more accurate than the non AI ones and it is clear
that each of the state-of-the-art modeling, inferencing and decision making methods are able
to predict the surface roughness and tool wear in a non intrusive manner (Torabi et al. 2009). In
fact, nowadays soft computing tools are extensively used to model and control of machining
processes (Tarng and Hwang 1995; Markos et al. 1993). A fuzzy model can be obtained using
a description language based on FL statements. It is importance in the modeling has been a
research issues since decades ago. In the modeling, many techniques have been applied from
conventional mathematical modeling such as regression, Response Surface Methodology
(RSM) until the AI techniques such as GA, ANN, FL, and PSO. The learning speed and
flexibility of the AI structure to deal with the changes of the system are the challenges to
the new approaches. Based on further research by Hermann (1990), AI has been applied in
monitoring machining system. A review by Abellan-Nebot and Subiron (2010) showed the
details of AI techniques in machining monitoring system. Pham and Pham (1999) further
reviewed five of these AI tools, there are; knowledge-based systems (expert system), fuzzy
logic (rule base), inductive learning, neural networks and genetic algorithms which have been
existence for more than 30 years. Application of AI for modeling and optimizing machining
parameters were reported by several studies previously. AI techniques for optimization of
machining cutting conditions which are considered by previous studies include GA (Zain
et al. 2011a,b, 2010a; Singh and Rao 2007), SA (Zain et al. 2011c,d, 2010b; Bharathi and
Baskar 2010; Rao and Pawar 2010b), ACO (Kadirgama et al. 2010; Wu and Yao 2008;
Vijayakumar et al. 2003), PSO (Bharathi and Baskar 2011; Farahnakian et al. 2011; Yang et
al. 2011a,b; Rao et al. 2010a). Modeling techniques for modeling machining performances
are such as FL (Syn et al. 2011; Dong and Wang 2011; Ren et al. 2011) and ANN (Zain
et al. 2010c). Hybrid systems, which are combination of two or more branches of AI, have
been widely used by researchers in various fields, such as engineering, economics, medicine,
atmospheric phenomenon, military, and marine. They have been applied for identification,
optimization, prediction, forecasting, modeling and control of complex systems (Mellit et al.
2009). Some previous researches applied hybrid systems with the target to obtain optimal
solutions of machining cutting conditions. For example, ANN integrated with PSO was used
to optimize the cutting conditions subject to a comprehensive set of constraints, which are
feed and speed for a typical case found in industry, namely, pocket-milling (Tandon et al.
2002). ANN and PSO were also hybridized in determining the optimal cutting conditions for
the ball end milling machining process, and it was found that the feed rate has a dominant
effect on the machining efficiency (El-Mounayri et al. 2005). Focused on the depth of cut
of machining performance in abrasive water jet (AWJ) which is classified as the modern
machining process, FL was hybridized with GA in determining the best combination for
the cutting conditions such as waterjet pressure, jet traverse rate and abrasive flow rate
(Chakravarthy and Babu 2000). ANN hybridize with GA can be effectively utilized to find
the best or optimum cutting conditions values in end milling Inconel 718 (Ozcelik et al.
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Fuzzy logic for modeling machining process
2005). ANN was hybridized with GA in predicting the depth of cut for AWJ process by
considering cutting conditions such as water pressure, abrasive flow rate and jet traverse rate
(Srinivasu and Babu 2008). ANN and GA were hybridized for optimizing creep feed grinding
(CFG) machining process in obtaining the maximum metal removal rate and the minimum
surface roughness, Ra (Sedighi and Afsahri 2010). Integration of ANN and GA was used for
researching for the optimal cutting conditions of the finish mould surface with using bound
abrasives (Wang et al. 2012). ANN and GA were hybridized for optimal cutting conditions of
electric discharge machining (EDM) process (Wang et al. 2003; Krishna et al. 2009). ANN
and GA were hybridized to model and optimize the cutting conditions for AISI 10140 steel
material with TiA1N solid carbide tool under wet condition (Oktem 2009). ANN and GA
were also hybridized, labeled as genetically optimized neural network system (GONNS), for
selection of optimal cutting conditions from the experimental data with minimum operator
involvement (Aykut et al. 2010).
In manufacturing, machining is one of process which encompassing a broad range of
technologies and techniques. There are two main practical problems that engineers face in
a machining process. First is to determine the parameter values of the process that will
yield the desired product quality (meet technical specifications). Second is to maximize
manufacturing system performance using the available resources (Benardos and Vosniakos
2003). Azadegan et al. (2011) suggests for a popular emphasis in the use of fuzzy tools in
certain aspects of manufacturing and a specialized application. Chandrasekaran et al. (2010)
discussed four machining type namely turning, milling, grinding and drilling. Machining is
defined as a process to remove metal in the form of chips using single or multiple wedge-
shaped cutting tools to produce the desired shape. There are two type of machining process
namely conventional and modern machining process. The detail of these two categories is
explained in Sect. 3. Machining process can be represented as a mathematical process in
optimizing the process. The representation is called modeling. Important role in input-output
parameter relationship modeling can be assigned by FL technique. The fuzzy modeling
technique is applied when subjective knowledge and suggestion by the expert are significant
in defining objective function and decision variables (Jaya et al. 2010).
The important role of FL consists of five issues viz., purpose of FL applied in machining,
application of FL in modeling of modern and conventional machining process, role of FL in
order to investigate machining parameter, defuzzification of FL used in machining process
and membership function of FL applied in machining process. All of these five important
roles of FL will be discussed further on the following sections. Scope of this discussion is
limited on how FL is applied in modeling a machining process. In term of the significance
of FL in modeling of machining process, this paper is written to review and to study the
importance of FL in modeling, and to present the abilities, limitations and improvements
of FL as AI tools in modeling of machining process. Therefore, the analysis presented in
this paper is expected to investigate the purpose of FL in modeling machining process and
expected the contents of this paper will lead to a new conclusion on the importance and
relevance of FL in the modeling.
Searching of preferences are based on the keyword modeling of machining processes,
artificial intelligence applied in machining processes and FL in modeling of machining
processes. The selection is based on the relation of keyword AI, FL, modeling and machining
process. Based on these references, this paper presents overview of the FL technique in
modeling of machining process for various purpose associated with the model. Scope of this
discussion is limited on the how FL is applied in modeling a machining process.
This paper is divided into five sections. In Sect. 1, introduction is given and followed by
briefly discussion on scope, objective and definition of AI and machining process. Section 2
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provides a brief outline of the FL, machining process and the analysis on the application
of FL in machining process. Section 3 presents the result of analysis conducted on the
application of FL in modeling machining process. The discussion is divided into five types
of analysis namely on the purpose of modeling machining process in FL, application of
FL in conventional and modern machining process, discussion on machining performance
modeled with FL, analysis on defuzzification of FL used in machining process, and analysis
on membership function of FL used in machining process. Section 4 revealed about the
abilities, limitations and improvements of FL in machining process based on the previous
comments from experiment conducted by previous researchers. The summaries and future
work are presented in Section 5.
2 Overview of fuzzy logic and machining process
This section will briefly discuss about definition of FL, type of machining process, and
discuss the relation between FL and machining process. FL is a convenient way to map
an input space to an output space. FL is a precise logic of imprecision and approximate
reasoning (Zadeh 2008). In Sect. 2.1, this section will discuss six important term in fuzzy
namely fuzzy system, fuzzy inference, fuzzy sets, fuzzy rules, membership function (MF),
and defuzzification. The definition, importance and relation of these six important terms are
based on the previous work done by others researchers. In Sect. 2.2, this section will discuss
the definition of machining process consists of conventional and modern machining process.
Machining is defined as a process, in which the metal is removed in the form of chips by
means of single or multiple wedge-shaped cutting tools. Section 2.3 will discussed about the
relation between FL and machining process.
2.1 Fuzzy logic
Fuzzy systems (FS) are based on fuzzy set theory and associated techniques pioneered by
(Zadeh 1965). Zadeh (1965) paper contains the ideas of modeling and controlling very com-
plex cases such as nonlinear system through an expert system. Zadeh is the person mainly
responsible for the success of fuzzy control using two basic theoretic contributions, the
so-called Generalized Modus Ponens Scheme for imprecise reasoning, and the Composi-
tional Rule of Fuzzy Inference that gives the algorithm’s output, as well as the definition of
Linguistic Variables and the ways of representing and computing with them. Both contri-
butions are today in the armamentarium of any FL practitioner (Trillas 2011). FS may be
less precise than conventional systems but are more like our everyday experiences as human
decision-making (Mellit et al. 2009). Fuzzy inference system is associated with number of
names, such as fuzzy-rule-based systems, fuzzy expert system, fuzzy logic controller, fuzzy
model, fuzzy associative memory and simply (and ambiguously) fuzzy system (Jang and Sun
1995). FL may be viewed as an attempt at formalization/mechanization of two remarkable
human capabilities. First, the capability to converse, reason and make rational decisions in
an environment of imperfect information. Second, the capability to perform a wide variety of
physical and mental tasks without any measurements and any computations (Zadeh 2008).
Fuzzy inference is the process of formulating the mapping from a given input to an
output using FL. The mapping then provides a basis from which decisions can be made.
The process of fuzzy inference involves membership functions, FL operators, and IF-THEN
rules. A Membership Function is a curve that defines how each point in the input space is
mapped to a membership value (or degree of membership) between 0 and 1. There are two
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types of fuzzy inference systems namely that are Mamdani-type and Sugeno-type (Sharma
et al. 2008). FL is based on the concept of fuzzy sets. A fuzzy set is a set without a crisp,
clearly defined boundary that is, it can contain elements with a partial degree of membership
(usually between 0 and 1). A more strict definition is that a fuzzy set m of x is a function
from the set x to the unit interval, i.e. m:x [0,1]. The function that defines how each element
is mapped to the degree of membership is called the membership function (MF) (Benardos
and Vosniakos 2003).
Mamdani method was among the first control systems built using fuzzy set theory. It
was proposed in 1975 by Mamdani and Assilian (1975) and King and Mamdani (1977) as
an attempt to control a steam engine and boiler combination by synthesizing a set of lin-
guistic control rules obtained from the effort was based on Zadeh (1973) paper on fuzzy
algorithms for complex systems and decision processes. The basic idea is much the same.
Mamdani style inference expects the output membership functions to be fuzzy sets. After
the aggregation process, there is a fuzzy set for each output variable that needs defuzzi-
fication. It is possible, and in many cases much more efficient, to use a single spike as
the output membership functions rather than a distributed fuzzy set. It enhances the effi-
ciency of the defuzzification process because it greatly simplifies the computation required
to find the centroid of a two-dimensional shape. Rather than integrating across a contin-
uously varying two-dimensional shape to find the centroid, we can just find the weighted
average of a few data points. Sugeno (1985) support this kind of behavior. It is similar to
the Mamdani method in many respects (Takagi and Sugeno 1985). In fact the first two parts
of the fuzzy inference process, fuzzifying the inputs and applying the fuzzy operator, are
exactly the same (Yilmaz et al. 2006). The output membership function is determined by
the types of inference system selected either Mamdani or Sugeno. In the Mamdani infer-
ence system, the output membership function is fuzzy sets; in the Sugeno type, the output
membership function is linear or constant (Liu et al. 2010). The main difference between
Mamdani and Sugeno models is that the output membership functions of Sugeno could either
be constant or linear while the output membership functions are nonlinear in Mamdani mod-
els. Takagi–Sugeno models were preferred because of their ease of use (Aliustaoglu et al.
2009).
FS commonly have four components: consists of a fuzzifier process, fuzzy rule base,
inference engine, and a defuzzifier process (defuzzification). Fuzzification is a process that
classifies numerical measurements into fuzzy sets. The rule base contains the IF-THEN rules
that embody linguistic reasoning. An inference engine applies the rule base to the fuzzy sets
to obtain a fuzzy outcome (Kor et al. 2010).
The fuzzy rule base is generated by the training algorithms via input–output data pairs,
and the fuzzy rules are expressed in the IF-THEN form. The fuzzifier can transform crisp or
fuzzy set data into suitable linguistic values by the definition of linguistic variables the types
of membership function (MF), such as Triangular, Trapezoidal, Gaussian, or Bell MFs. The
MF will map each element of the input variables into a membership grade between 0 and 1.
The inference engine performs approximate reasoning to achieve a desired strategy. Finally,
a defuzzification is used to yield a non-fuzzy decision or a crisp output by a strategy such as
the centroid of an area or the maximum size of an area (Lou and Chen 1999).
Fuzzy rules are set of linguistic statements which establish the relationship between the
input and the output in a fuzzy system. They are defined based on experimental work, expert
and engineering knowledge. The relationship between inputs and output in a fuzzy system
is characterized by set of linguistic statements which are called fuzzy rules (Hashmi et al.
2003a). The number of fuzzy rules in a fuzzy system is related to the number of fuzzy
sets for each input variable (Hashmi et al. 2003b; Yilmaz et al. 2006; Iqbal et al. 2007a).
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One of architecture of fuzzy expert systems was proposed by Kaur and Kaur (2009). In the
architecture, the relation between fuzzy rules and membership function has been established
in development of fuzzy inference engine and knowledge acquisition facility. In fuzzy rule,
there are consists of IF-THEN form which is expressed the relation between machining
parameters and machining performance. The numbers of fuzzy rule might give an impact
for the result of the FL modeling process. Previous researches used the data sets of the case
studies given as the number of fuzzy rules in order to develop the fuzzy rules.
In fuzzy rule, there are two methods commonly used to yield the aggregation of the fuzzy
rules that are Max–Min Inference Method and Max-Product Method. All the fuzzy “AND”
and “OR” operations are applied into all the input value of the corresponding fuzzy sets.
Applying a fuzzy “AND” operation will yield a result that is the minimum of the fuzzy value
of the number of input variables. The aggregation of the rule will be the truncation of the
output fuzzy set. This method is applied to all rules to obtain the final result which gives
the final shape of the output fuzzy membership function after aggregation of all the rules,
respectively. Then the union operation is applied to all the output fuzzy sets to yield the final
fuzzy set. The Max-Product method is similar to Max–Min Inference Method, except the
aggregation of the rule, instead of truncation; one would multiply the output fuzzy set with
the yielded result (Hashmi et al. 2003b).
Membership function (MF) is a curve that defines how each point in the input space
is mapped to a membership value (or degree of membership) between 0 and 1. The input
space is sometimes referred as the universe of discourse, a fancy name for a simple concept.
The simplest membership functions are formed using straight lines. Triangular, Trapezoidal,
Gaussian, Generalized bell, Sigmoidal and Polynomial are the curve that perform member-
ship function. Triangular functions are commonly applied because of their simplicity and
because they are easy to implement in a computer program and they can approximate most
non-triangular ones (Kor et al. 2010). Fuzzy controller needs an expert’s knowledge or an
operator’s experiences are needed for establishing appropriate control rules and membership
functions (Huang and Shy 1999).
Defuzzification is the conversion of a fuzzy quantity to a precise quantity, fuzzification
that is the conversion of a precise quantity to a fuzzy quantity. It has been proposed by
investigators in recent years, among popular for defuzzification methods: centroid, bisector,
Mean of Maximum (mom), Largest of Maximum (lom) and Smallest of Maximum (som). The
selection centroid of area defuzzification method is used because it has been used generally
and gives more reliable results than the others (Hashmi et al. 2003a). Furthermore, the center
of area defuzzification method is suitable for a multidimensional fuzzy output. The resultant
membership functions are developed by considering the union of the output of each rule,
which means that the overlapping area of fuzzy output sets is counted only once, providing
more results (Yilmaz et al. 2006). The selection of the defuzzification technique is critical
and has a significant impact on the speed and accuracy of the fuzzy model. Defuzzification
refers to the way a crisp value is extracted from a fuzzy set as a representative value. The
most frequently use defuzzification strategy is the centroid of area. These defuzzification
methods are computation intensive and there is no rigorous way to analyze them except
through experiment-based studies (Jang and Sun 1995).
Additionally, a modeling based on FL is primarily measured by two features to show the
quality of the proposed model: interpretability and accuracy (Casillas et al. 2003; Alcalá et
al. 2006). Interpretability refers to the ability of FL to express the behavior of the system in a
reasonable way. This ability could be satisfied by finding appropriate number of fuzzy rules,
number of linguistic terms, and the shape of fuzzy sets. Accuracy refers to the ability of FL
to truly represent the modeled system. This ability could also be satisfied by considering
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proper and correct membership functions, linguistic terms and rules. All in all, there should
be a trade-off between interpretability and accuracy (Alcalá et al. 2005).
2.2 Machining process
Machining is defined as a process, in which the metal is removed in the form of chips by
means of single or multiple wedge-shaped cutting tools. The machining process involves
physical phenomena that are very difficult to describe accurately using traditional mathemat-
ical models because of the essence of the process itself; this is the main reason why there are
no such models available. Chandrasekaran et al. (2010) present review paper on the appli-
cation of AI techniques in machining performance prediction and optimization is limited
to conventional machining processes and does not include the relatively newer machining
processes such as ECM, EDM, ECDM, etc. In conventional machining processes, the atten-
tion has been paid by the author to four commonly used processes such as turning, milling,
drilling, and grinding. But in this paper review, conventional and modern machining process
such as turning, milling, drilling, grinding, boring, EDM, ECM, ECDM, WEDM and laser
has been reviewed from other researchers. Turning is used for producing axis symmetric
components, milling for producing flat or curved surfaces and prismatic shapes, drilling for
making holes, and grinding for improving the surface finish and/or for maintaining them
tolerances. These processes are performed by conventional and computer numerically con-
trolled (CNC) machine tools (Chandrasekaran et al. 2010). The following paragraphs briefly
explain machining process is defined by few researchers.
Milling is a multipoint tool cutting process in which the cutter rotates at some speed
while the work feeds past the cutter (Chandrasekaran et al. 2010). Surface is generated
progressively by the removal of chips from a work piece as it fed to a rotary cutter in a
direction perpendicular to the axis of the cutter. There are two common methods of milling:
peripheral milling and down milling. In peripheral milling (up-milling), a surface is generated
by a teeth located on the periphery of the rotary cutter that is rotating in the direction opposite
to that of the feed of the work piece. The second one is down milling; in this case the cutter
rotates in the same direction as that of the feed of the work piece (AI-Wedyan et al. 2001).
Grinding is a surface finishing process, and surface roughness is one of the most important
factors in assessing the quality of a ground component (Kor et al. 2010). Drilling is a process
of making a cyclindrical hole in a solid workpiece using a cutting tool. The peripheral speed
of the drill called cutting speed, movement of the drill along the axis of the hole for one
revolution called feed and radius of the drill called as depth of cut are the process parameter
(Chandrasekaran et al. 2010). Turning is used to reduce the diameter of the workpiece, usually
to a specified dimension, and to produce a smooth finish on the metal. In turning processes, a
single point cutting tool moves along the axis of a rotating workpiece (Chandrasekaran et al.
2010). Turning also used to produce rotational, typically axi-symmetric, parts that have many
features, such as holes, grooves, threads, tapers, various diameter steps, and even contoured
surfaces. Boring is a process in which pre-drilled holes or holes in cast, forged or extruded
components are enlarged or finished with a cutting tool mounted on a boring bar. The process
is mostly used in applications where close dimensional tolerances and good surface finish
are required (Yussefian et al. 2008).
Electrical discharge machining (EDM) uses electrical spark or thermal energy to erode
unwanted material in order to create desired shape. EDM is a non-traditional concept of
machining which has been widely used to produce dies and molds. The material is removed
with the erosive effect of the electrical discharges from tool and work piece (Abbas et al.
2007). EDM is a thermal removal process extensively used for die manufacturing in industry.
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It is the most common process together with the CNC milling in the manufacture on plastic
injection moulds. Mould-dies are usually machined on CNC machining centers (Yilmaz et
al. 2006). EDM comes in two basic types: wire and sinker (die sinking). Wire electrical
discharge machining (WEDM) is used primarily for shapes cut shapes through a selected
part or assembly. WEDM is a manually dependent process since many machining parameters
are determined by experienced operators in practice. The development of the process was
the result of seeking a technique to replace the machined electrode used in EDM. During
the WEDM process, the material is eroded a head of the wire and there is no direct contact
between the workpiece and the wire, eliminating the mechanical stresses during machining
(Ho et al. 2004). With WEDM machine, if a cutout needs to be created, an initial hole must
first be drilled in the material, and then the wire can be fed through the hole to complete
the machining. Sinker (die sinking) EDMs are generally used for complex geometries where
the EDM machine uses a machined graphite or copper electrode to erode the desired shape
into the part or assembly. Sinker EDM can cut a hole into the part without having a hole
pre-drilled for the electrode.
Electro chemical machine (ECM) is used to produce complicated shapes of varying sizes
with electrically conductive but difficult to machine materials. Further research is conduct by
(Rao et al. 2009). Electrochemical discharge machining (ECDM) is a hybrid non-conventional
manufacturing process which combines the features of ECM and EDM. The ECDM process
consists of a cathodic tool and an anodic workpiece, which are separated by a gap filled
with electrolyte, and pulsed direct current (DC) power applied between them. This leads to
electrical discharges between the electrodes, thus achieving both electro chemical dissolution
and electro discharge erosion of the workpiece (Mediliyegedara et al. 2005). Laser is works
by exciting a gaseous medium, commonly carbon dioxide, causing it to amplify light reflected
back and forth multiple times within the laser chamber. The light emerges from an aperture
and is focused by a lens onto a specific point. It is flexible process in mould making of
filigree structures. This process is suitable for machining difficult-to-machine materials, like
ceramics, carbide and hardened steel with excellent productivity and surface quality (Kaldos
et al. 2004).
2.3 Discussion
This section will discuss the relation between the FL and machining process. FL is about
a precise logic of impression and approximate reasoning. The idea is modeling and con-
trolling very complex cases into simple method. It is more about our everyday experiences
as human thinking. In FL, it consists of fuzzifier process, rules, membership function, and
defuzzification. In machining process; machining parameter and machining performance is
referred to an input and output of the machining respectively. Machining parameter can be
feed rate, depth of cut, cutting speed, and rake angle. Machining performance might be sur-
face roughness, cutting force, material removal rate, and tool life. Common features of FL
and machining are both of them posses input and output. The model can be expressed by
IF-THEN rules. The IF criteria belong to FL input feature while THEN criteria belong to
output features. These features is related to the machining process in term of the input of
FL for machining process is machining parameter while the output of FL for machining
process is machining performance. So the IF-THEN rules implied in FL can be selected as
the best output in the defuzzification process. The combination of the input and output which
expressed in IF-THEN rules, might produced the best combination statement for solving
machining problems. Therefore, experts (real machinists) might produced desired product in
shorter time and reduce operational cost.
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3 Analysis on the application of fuzzy logic for modeling machining process
This section is focusing on the purpose of FL in modeling of machining process, followed by

analysis on the application of FL in modeling conventional and modern machining process,
and lastly discussing the machining process that has been applied by FL.
3.1 The purpose of fuzzy logic in modeling of machining process
This section presents and relates the FL in modeling of machining process with purpose such
as in prediction, optimization, control, selection, and monitoring. A systematic approach
of modeling and determination of optimal or near-optimal cutting conditions has shown an
interesting potential in both product and process quality improvement of metal cutting oper-
ation (Mukherjee and Ray 2006). FL can be used to build process models on the basis of
the expertise of human operators. FL is one such intelligent technique and proven useful in
control. Depending on the purpose, it shows based on the literature review that FL can be
useful tools in representing and modeling a machining process for many purposes. Based
on the literature, it can be concluded that FL that has been used in modeling of machin-
ing process is to solve machining problems such as predicting surface roughness in term of
machining performance, optimizing tool life in machining process, control machining para-
meter of machining process, selection of machining parameters, and monitoring tool wear
and maximize.
The prediction of cutting behavior and optimization of machining parameters has been hot
areas of research. In prediction of machining performance, Kamatala et al. (1996) develop
a fuzzy set theory-based system for predicting surface roughness in a finished turning oper-
ation. Aguero et al. (1994) applied FL to obtain cutting process on a milling machine. The
prediction of surface roughness, cutting force, and tool life in machining is a challenging
task, but is necessary for proper optimization of the process (Chandrasekaran et al. 2010).
In optimization, Lin et al. (2000) applied Taguchi method with FL for optimizing the EDM
process with multiple performance characteristics has been reported. In order to control a
process parameter, Ralston et al. (1992) used FL to control of chip form (cutting condition).
Application of FL to monitoring and control of metal working processes were reviewed by
(D’Errico 2001). Seven types of purpose related to modeling using FL have been analyzed.
Tables 1 and 2 shows some of the previous work related to FL modeling in machining process.
Figure 1 shows the analysis on purpose of machining model. Based on these, it shows that
prediction of machining performance was contributing the main reason of application of FL
for machining modeling. It can be concluded that prediction is very important in application
of modeling machining process in order to produce the desired product. The desired product
quality can be obtained and improved by predict the machining performance before start the
actual process.
3.2 Application of fuzzy logic for conventional and modern machining process
3.2.1 Conventional machining process
Conventional machining is generally regarded as using manually controlled machines. The

tool moves around the work by mechanical controls that are manually controlled. Conven-
tional also known as traditional machining process consists of several type of machining
process namely turning, milling, drilling, grinding and boring. This section concludes the
application of FL in conventional machining process based on the previous researchers work.
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Table 1 Example of previous work for application of fuzzy logic for conventional machining process
No Author, Machining Membership Logical Type of Defuzzi- Rule No of Machining Machining Remarks
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year process functions operations fuzzy fication aggregations Rules parameters performance
1. Haber et al. Drilling Triangular Not stated Not stated Centroid Max-min 49 Feed rate and Cutting force Optimal fuzzy controller reduces
(2010) depth of cut the influence of the increasing
cutting force that occurs as the
drill depth increases
2. Gill and Drilling Gaussian AND TSK Not Stated Not stated 4 Depth of Material FL system was found to be very
Singh penetration, removal flexible and easy to comprehend
(2010) Time of rate and hence can act as an
penetration alternative to the conventional
and modeling techniques
Penetration
rate
3. Drilling Trapezoidal AND Mamdani and Centroid Not Stated Polynomial = cutting speed, Surface Fuzzy rule based model (FRBM)
Nandi and Paulo and TSK 27 rules feed rate and roughness with TSK-type fuzzy rules
Davim (2009) Polynomial Trapezoidal rate of and torque describes excellent trade-off
= 8 rules lubrication with experimental
measurements
4. Haber et al. Drilling Triangular Not stated Not stated Centroid Max-product 49 Feed rate and Cutting force Optimal fuzzy control system
(2010) spindle speed reduces the influence of the
increase in cutting force that
occurs at larger drill depths
5. Biglari and Drilling Trapezoidal AND and OR Not stated Centroid Max-min 53 Feed rate Thrust force, Fuzzy controller is capable of
Fang torque, simulating human experience,
(1995) radial force intelligence and reasoning
and tool during control of small-hole
wear drilling processes
6. Dong and Milling Gaussian AND TSK Not stated Not stated 27 Spindle speed, Surface ANFIS with LOO-CV approach
Wang feed rate and roughness provide an effective way for
(2011) depth of cut prediction of surface roughness
in end milling process
Table 1 continued
7. Kim and Jeon Milling Triangular Not stated Not stated Not stated Not stated Not stated Feed rate, Cutting force A fuzzy-logic controller
(2011) spindle speed, (FLC) is designed to
depth of cut automatically adjust
and mill federate in order to regulate
diameter the cutting force of milling
processes in a vertical
machining center
8. Uros et al. Milling Triangular Not stated Not stated Not stated Not stated 32 Spindle speed, Flank wear ANFIS model has a high
(2009) and Trape- feed rate, and cutting accuracy for estimating
zoidal depth of cut force flank with small

and no of computational time
flutes
9. Ho et al. Milling Gaussian AND Not stated Not stated Not stated 27 spindle speed, Surface HTGLA is applied in the
(2009) feed rate and roughness ANFIS to determine the
depth of cut most suitable membership
functions and to
simultaneously find the
optimal premise
10. Miao and Li Milling Gaussian AND Not stated Centroid Max-product Not stated Radial depth of Cutting force The work introduces a
(2009) cut, axial generic method to predict
depth of cut the cutting force for
and feed rate, different type of workpiece
and tool material
11. Iqbal et al. Milling Triangular Not stated Not stated Centroid Max–min 16 Material Tool life, Fuzzy expert system proves
(2007a) and mean hardness, surface to be very effective and
of maxima tool’s helix roughness, efficient for optimizing the
angle, milling and cutting hard-milling process and
orientation, forces also to provide important
and coolant predictions before start of
actual process
123
Table 1 continued
123
12. Haber et al. Milling Trapezoidal AND Not stated Centroid Max-product 49 Feed rate and Torque Fuzzy controllers can be a
(2007) spindle speed very appropriate choice for
network-based control
applications since it does
not require an exact plant
model and measurement of
network-induced delay
13. Morgan et al. Milling Trapezoidal AND Mamdani Centroid Max-min 36 Spindle speed, Cutting FL is a sufficiently robust
(2007) feed rate, force method to handle the
cutter diversity of dynamic
geometry, analysis data en countered
depth of cut, within the milling process
milling
orientation,
part tolerance
and the
maximum
spindle speed
of machine
tool
14. Lo (2003) Milling Triangular AND TSK Not stated Not stated 27 Spindle speed, Surface The comparison indicates that
and Trape- feed rate and roughness the adoption of both
zoidal depth of cut triangular and trapezoidal
membership functions in
ANFIS achieved very
satisfactory accuracy for
prediction of workpiece
surface roughness in end
milling
15. Dweiri et al. Milling Gaussian OR TSK Centroid Max-min Not stated Spindle speed, Surface ANFIS is a technique that can
(2003) feed rate, roughness be used efficiently to
depth of cut optimize the CNC down
and number of milling machining of
flutes Alumic-79
Table 1 continued
No Author, Machining Membership Logical Type of Defuzzi Rule No of Machining Machining Remarks
16. Susanto and Milling Triangular AND Not stated Centroid Max-product Not Stated Feed rate and Tool wear The FL-ITWM system was
Chen depth of cut demonstrated to be an
(2003) efficient and effective way
of monitoring the condition
of wear on the tool during
the cutting process
17. Chen and Milling Triangular AND Not stated Centroid Not stated 135 Feedrate, spindle Surface Neural fuzzy system is shown
Savage speed, depth roughness to predict surface
(2001) of cut, roughness with 90 %
vibration prediction accuracy during
average per a milling operation
revolution,
tool diameter,
tool materials,
and workpiece
material
18. Peres et al. Milling Triangular Not stated Not stated Centroid Max-product Not stated Feed rate, Cutting force The fuzzy model and
(1999) and Trape- spindle speed hierarchical fuzzy control
zoidal and cutting integration was a natural
depth and necessary step because
it would give an
understanding of the
behavior of this
hierarchical concept
19. Lou and Milling Triangular AND Not stated Centroid Not stated 79 Spindle speed, Surface Surface roughness can also be
Chen vibration, feed roughness predicted with a 96 %
(1999) rate and accuracy rate by ISRR
cutting depth using the neural fuzzy
system
20. Haber et al. Milling Trapezoidal AND Not stated Centroid Not stated Not stated Spindle speed, Cutting force Fuzzy control strategy
(1998) feed rate, ensures that users and
cutting depth manufacturers will have
and material flexibility
hardness
123
Table 1 continued
year process functions Operations fuzzy fication aggregations Rules parameters performance
123
21. Ko and Cho Milling Triangular AND Not stated Centroid Max-min Not stated Cutting speed, Flank wear The fuzzy estimator using a
(1993) feed rate and fuzzy inference method
depth of cut with a max-min
composition rule,
combined with the
preprocessor, is an
efficient tool for
evaluating the minor flank
wear length
22. Gajate et al. Turning Gaussian AND Mamdani Centroid Not stated Not stated Time, cutting Tool wear rate The obtained results
(2012) forces, demonstrate that the
vibrations and proposed neuro-fuzzy
acoustic systems (ANFIS,
emissions DENFIS and TWNFIS)
signals are capable of dealing
with the non-linearity and
the uncertainties of the
tool wear process
23. Kirby et al. Turning Triangular AND Not stated Centroid Max-min Not stated Feed rate, Surface Fuzzy-nets model created a
(2006) spindle speed, roughness system capable of
and tangential detecting surface
vibration roughness and adapting
the feed rate to decrease
the surface roughness to
the desired value or
slightly below
24. Abburi and Turning Triangular AND Not stated Not stated Not stated 96 Cutting speed, Surface It is observed that the
Dixit cutting depth, roughness IF–THEN set of rules
(2006) feed rate, and provide as good
acceleration of prediction of surface
radial roughness as the neural
vibration networks
25. Lian et al. Turning Triangular AND Not stated Not stated Max-min Not stated Feed rate, depth Cutting force The GPFC can reduce the
(2005) of cut and difficulties in determining
voltage an appropriate
membership function and
fuzzy rules
Table 1 continued
26. Jiao et al. Turning Gaussian and AND TSK Not stated Not stated Not stated Cutting speed, Surface The FAN network has both
(2004) Triangular feed rate and roughness the learning ability of
depth of cut neural network and
linguistic representation of
complex, not well
understood, vague
phenomenon
27. Ho et al. Turning Bell-shaped Not stated Not stated Not stated Not stated Not stated Cutting speed, Surface ANFIS-based method
(2002) feed rate, roughness outperforms the existing
depth of cut polynomial network-based
and gray level method in terms of
modeling and prediction

accuracy
28. Nandi and Grinding Triangular AND Not stated Not stated Not stated 64 RPM of wheel, Surface The GA-tuned FLCs are able
Pratihar and RPM of work roughness to predict surface finish and
(2004) Polynomial and feed rate and power power requirement in
require- grinding with minimum
ment error for a set of input
parameters
29. Ali and Grinding Polynomial AND Not stated Not stated Max-min 100 Depth of cut, Surface Fuzzy model is shown to be
Zhang wheel speed, roughness simpler, more effective,
(1999) material superior in modeling
hardness, table non-linearity, and
speed, grit conceptually clearer than
size, dressing many other approaches
condition, and
wheel grade
30. Simoes and Boring Not Stated AND Mamdani and Not stated Not stated TSK = 114 Machine Machine Fuzzy model supported
Kim (2006) TSK rules diameter, utilization prediction of TBM
mamdani RQD, RMR, level utilization level and
= 375 and demonstrated to be useful
rules Groundwater for planning stage of TBM
inflow rate project
123
Table 2 Example of previous work for Application of Fuzzy Logic for Modern Machining Process
No Author, Machining Membership Logical Type Defuzzi- Rule No Process Machining Remarks
123
year process functions operations of fuzzy fication aggregations of rules parameters perfor-
mance
1. Rao et al. ECM Triangular AND Mamdani Not stated Not stated 81 Current, Material The optimal FLC is
(2009) voltage, flow Removal evolved with the help of
rate and gap rate and a genetic algorithm
between Surface
work piece roughness
and the tool
2. Maji and EDM Triangular Not stated TSK Not stated Not stated 9 Peak current, Material Adaptive network-based
Pratihar and Bell pulse-on- removal fuzzy inference system
(2010) shaped time and rate is found to tackle the
pulse-duty- (MRR) problems of forward
factor and and reverse mappings
surface efficiently in EDM
roughness
3. Shih and EDM Triangular Not Stated Not stated Centroid Not stated Not stated Gap voltage, Drilling The fuzzy logic controller
Kao spark ratio, time was demonstrated to be
(2008) and change advantageous in deep
of spark and small-diameter
ratio micro-hole EDM
drilling due to its
adaptability to different
EDM configurations
4. Yilmaz et al. EDM Triangular AND Mamdani Centroid Not stated 125 Discharge Electrode Fuzzy model for selecting
(2006) current, wear EDM parameters
pulse ratio, describes strategies and
duration and surface actions of skilled EDM
pulse roughness operators
interval and
erosion
rate
Table 2 continued
mance
5. Lin et al. EDM Trapezoidal AND Not stated Centroid Max-min 27 Pulse on time, Electrode Orthogonal array with the
(2002) duty factor, wear grey relational analysis
and ratio, method is more
discharge material straightforward than the
current removal fuzzy-based Taguchi
rate, and method for optimising
surface the EDM process with
roughness the multiple process
responses
6. Zhang et al. EDM Trapezoidal AND Not Stated Not stated Not stated 49 Position error, Step Adaptive fuzzy control
(2002) and Tri- change rate direction meets the actual control
angular of position and run requirement s very well
error and frequency
orientation
error
7. Lin et al. EDM Trapezoidal AND Not stated Centroid Max-min 9 Workpiece Electrode A fuzzy reasoning of the
(2000) polarity, wear ratio multiple performance
pulse-on and characteristics has been
time, duty material performed by the fuzzy
factor, open removal logic unit
discharge rate
voltage,
discharge
current and
dielectric
fluid
8. Skrabalak ECDM Triangular AND Not stated Centroid Max- 9 Current and Material Fuzzy-logic and
et al. product voltage removal especially adaptive
(2004) rate fuzzy-logic control
system may help in
reducing the number of
micro cracks and
surface roughness
parameter
123
Table 2 continued
123
mance
9. Caydas et al. WEDM Gaussian AND TSK Not stated Max-min 2 Pulse duration, White layer ANFIS can greatly
(2009) open circuit thickness improve the process
voltage, and responses such as
dielectric surface surface roughness and
flushing roughness WLT in the WEDM
pressure and process
wire feed
rate
10. Yuan et al. WEDM Gaussian AND Mamdani Centroid Not stated Not stated Workpiece Material Combining very rough
(2009) and Tri- thickness, removal fuzzy prior model with
angular peak current, rate and training examples still
on- time and surface significantly improves
off-time roughness the predictive
performance of WEDM
process modeling, even
with very limited
training data-set
11. Yan and WEDM Triangular AND Not Stated Mean-of- Max-Prod 49 Wire tension Control FLC with retrofitted wire
Fang and maximum error and voltage transport mechanism
(2008) Trape- change of contributes to a faster
zoidal wire tension transient response and a
error smaller steady-state
error under the influence
of flushing condition
12. Liao and WEDM Triangular Not stated Not stated Centroid Max-min Not stated Feed and pulse Power con- The use of this control
Woo off-time sumption system results in a very
(2000) and short satisfactory
circuit performance
ratio
Table 2 continued
mance
13. Syn et al. LBM Gaussian AND Mamdani Centroid Max-Prod 90 Laser power, Surface FL model is a suitable and
(2011) assist gas roughness practical technique that
pressure and and dross can be effectively used
cutting inclusion in the prediction of
speed carbon dioxide (CO 2)
laser cutting process
with minor error rates.
14. Sivarao et al. LBM Triangular AND Mamdani Bisector Not stated 128 stand off Surface Fuzzy model has shown
(2009) distance, roughness that the ability to predict

focal output from given input
distance, gas of the laser cutting
pressure, machine is achieved
power,
cutting
speed,
frequency
and duty
cycle
15. Sivarao LBM Bell- AND Not stated Not stated Not stated 128 Stand off Kerf width ANFIS in generalization
(2007) shaped distance, of the modeling
focal technique has been
distance, gas successfully developed
pressure, to predict the cut edge
power, quality with excellent
cutting degree of accuracy
speed,
frequency
and duty
cycle
123
Fig. 1 Purpose of machining model using FL
Razali et al. (2011) deployed FL in this study to predict cutting speed and feed rate of
peripheral end milling process at given hardness of material, radial depth of cut and cutter
diameter. There were two types of fuzzy models had been designed and developed throughout
in his study. Two types of fuzzy model were designed to evaluate the effectiveness and
efficiency of introducing cutter diameter as another input into the system. Author concluded
the relationship between the material hardness, radial depth of cut and diameter of the tool
with recommended cutting speed and feed can be described by the theory of fuzzy sets.
Ren et al. (2011) presents the experimental study for turning process in machining by using
Takagi–Sugeno–Kang (TSK) fuzzy modeling to accomplish the integration of multi-sensor
information and tool wear information. The experimental results show its effectiveness and
a satisfactory comparison with several other AI methods. But for tool condition monitoring,
none of existing methods can overcome the defect that the models are difficult to estimate
the errors of approximation.
The design of an optimal fuzzy controller for cutting force regulation in a network-based
application and applied to the drilling process is described by (Haber et al. 2010). The
key issue is to obtain optimal fuzzy controller parameters that yield a fast and accurate
response with minimum overshoot by minimizing the integral time absolute error (ITAE)
performance index. The experimental results demonstrate that the proposed optimal fuzzy
control provides outstanding transient response without overshoot, a small settling time and a
minimum steady-state error. The application of optimal fuzzy control reduces rapid drill wear
and catastrophic drill breakage due to the increasing and oscillatory cutting forces that occur
as the drill depth increases. From a technical viewpoint, the optimal fuzzy controller reduces
the influence of the increasing cutting force that occurs as the drill depth increases, which
can produce rapid drill wear and catastrophic drill breakage. Gill and Singh (2010) includes
design and demonstration of the use of FL based model to simulate the material removal rate
in ultrasonic drilling of sillimanite ceramic. FL system was found to be very flexible and easy
to comprehend and hence can act as an alternative to the conventional modeling techniques.
FL allowed the modeling and on-line control problem to be treated simultaneously.
Nandi and Paulo Davim (2009) conduct experiments on the prediction of machining
performance with Minimum Quantity of Lubricant using FL in drilling process. It is observed
that for constant cutting speed, the cutting power/specific force requirement increases with
feed rate as well as with cutting speed when feed rate is kept as a constant value. Two different
types of FL rules and two different shapes of membership function distributions, MFDs are
used to construct fuzzy rule based model FRBMs in order to predict surface roughness,
cutting power and specific force requirement in drilling of Aluminium AA1050.
Iqbal et al. (2007a) applied FL to optimize the parameters in accordance with the objectives
of maximizing tool life, minimizing surface roughness, and also the attainment of both of
123
these simultaneously. FL proves to be very effective and efficient for optimizing the hard-
milling process and also to provide important predictions before start of actual process. Lin
et al. (2006) concentrated on how to determine feed rate according to material hardness, tool
diameter and cutting depth as process parameter using FL for end milling operation. In order
to obtain the inference knowledge for the FL model, a method composed with ANN and
data cluster is applied. The proposed FL can supply a new approach for expert system in
determination of machining parameters for milling operation.
Based on paper Hashmi et al. (2003b), fuzzy model that has been designed for selecting
cutting conditions for the turning operation uses two inputs and one output. Adjustment
approach applied to a FL based model for selecting cutting speed where the machining data
for speed ranges between the different depths cut are not overlapped. The application of FL
based model for selecting cutting speed in a turning operation for non-overlapping cutting
speed ranges is possible by using a superimposition scheme. Hashmi et al. (2000) applied
the FL model in drilling operation to select drilling speeds for three different materials:
carbon steels, alloy steel and free machining carbon steels. The author summarized that the
relationship of a given work-piece material hardness with the recommended drilling speed
can be described and evaluated by the fuzzy set theory. A standard fuzzy model can be used
for evaluating drilling parameters for different types of work-piece materials having a range
of hardness values.
Ali and Zhang (1999) propose a fuzzy model for surface roughness estimation that takes
many variables into account and covers a wide range of grinding conditions. Moreover, the
model can utilize the overwhelming experience gained over decades by experienced grinding
technicians, which cannot be done by any of the existing models. Up to 16 independent
variables can be used to estimate the surface roughness.
3.2.2 Modern machining process
Modern machining methods are classified according to the type of fundamental machining
energy employed, for example, mechanical, electrochemical, chemical or thermoelectric.
Modern machining is controlled by computers using CNC machine. Modern machining
method allows for high volume manufacturing of products. With modern machining tech-
niques, machinists have the ability to create almost any products or component imaginable.
Modern machining process permits better, faster and more cost effective flexibility of work,
which allows for manufacture of product with more complex and difficult angles or cuts.
Shabgard et al. (2012) introduces a fuzzy-based algorithm for prediction of material
removal rate, tool wear ratio and surface roughness in the EDM and ultrasonic-assisted EDM
processes. Discharge current, pulse duration and ultrasonic vibration of tool are the input
variables. The proposed fuzzy model provides a more precise and easy selection of EDM
and ultrasonic-assisted EDM input parameters for the required output parameters, which
leads to better machining conditions and decrease the machining costs with accuracies more
than 90 %. Comparison and validation of fuzzy results with experiment finding verified the
high accuracy of models.
Syn et al. (2011) conducted experiments a set of training and testing consists of 125 data
used in the FL model are arranged in a format of three input parameters that cover the power,
assist gas pressure and cutting speed, and two output which are the surface roughness and
dross inclusion. Thus, an attempt has been carried out to develop an expert system using
FL model to predict the effect of carbon dioxide (CO2 ) laser cutting quality based on laser
cutting parameters onto 1 mm thickness of Incoloy alloy 800. It shows that the proposed
FL model can be used to predict the surface roughness and dross inclusion of CO2 laser
123
cutting process for Incoloy alloy 800 with minor error rates. The changes of the functionality
steps in fuzzy inference process did affect on the statistical values root-mean-squared error,
absolute fraction of variance and mean absolute percentage error; however, it was found that
any changes of the ‘OR’ operation has no impact on the statistical values. Thus, changes
only can be made and examined on the ‘AND’, Implication, and Aggregation method. The
result of testing phase showed that the proposed fuzzy model with Prod-Max was capable
of generalizing between input and output variables with reasonably good prediction errors
where the statistical values were obtained in testing phase compared to Min-Max where
gave unreasonable values. Hashmi et al. (2003b) mentioned that by applying a fuzzy ‘AND’
operation will yield a result that is the minimum of the fuzzy value of the number of input
variables. ‘AND’ operation and Min-Max algorithm has been used by Hashmi et al. (2003b)
and yielded a minimum result on his experiments. It is evident that the Max-Product method
is similar to Max–Min Inference Method, the only difference being the aggregation of the
rule, instead of truncation, one would multiply the output fuzzy set with the yielded result.
Labib et al. (2011) paper presents the development of a FL to add intelligence to the
ECM process was improved through the integration of a FL into the existing control system.
The objective of the FL was to improve machining performance and accuracy by controlling
the ECM process variables. FL is shown to automate the ECM process, eliciting human
knowledge and integrating it into the ECM controller to give it intelligence which controls
the feed rate of the tool and the flow rate of the electrolyte. The existing controller consisted
manual machining to control the tool feed rate and collect real-time probe data every second.
The introduction of the new valve set allowed for the electrolyte flow rate to be controlled
using an upgraded version of the manual machining controller. The final upgrade phase for
the manual machining controller was the integration of the FL. Although the FL slightly over-
compensates for the critical current occurrence, this can be adjusted through ‘fine tuning’ of
the MF. What these results serve to prove is that FL can be used to gradually control the ECM
process. FL ensured that the machining process finished without any sparking incidences. In
the case of manual machining the human operator would manually adjust both the tool feed
rate and the valve position one after the other. FL allows the experience and knowledge of
the machine operator to be elicited into the process controller allowing it to act faster and
upon multiple machine variables. The results served to introduce innovative possibilities and
provide potential for future applications of FL in ECM.
Maji and Pratihar (2010) assigned three input parameters, such as peak current, pulse-
on-time and pulse-duty-factor, and two outputs, namely material removal rate and surface
roughness have been considered for the said mappings. Adaptive network-based fuzzy infer-
ence system (ANFIS) is found to tackle the problems of forward and reverse mappings
efficiently. In the present work, ANFIS models have been developed using both linear as
well as non-linear membership function distributions for the input variables in order to estab-
lish input–output relationships of the EDM process. The fuzzy inference system utilizing
non-linear membership functions is seen to perform slightly better than linear membership
functions for the input variables.
In a paper by Caydas et al. (2009) an ANFIS model has been developed for the prediction
of the white layer thickness (WLT) and the average surface roughness has been achieved
as a function of the process parameters. The model combined modeling function of fuzzy
inference with the learning ability ANN; and a set of rules has been generated directly from
the experimental data. The paper has presented the use of the ANFIS method based on the full
factorial experimentation for predicting surface roughness and WLT in the WEDM process.
As a result, this approach greatly improved the machining performances such as surface
roughness and WLT in the WEDM process.
123
Fig. 2 Machining processes dealt with fuzzy logic
A user-friendly fuzzy-expert system was developed by Yilmaz et al. (2006) for the selec-
tion of the EDM parameters has been introduced. In this system, discharge current, pulse
duration and pulse interval are the inputs while the outputs are electrode wear, surface rough-
ness and erosion rate. The developed fuzzy model allows many parameters that are diffi-
cult to measure to be taken into consideration. It has been shown that the system are easy
to use, provides a compact selection tool based on expert rules and enables an unskilled
user to select necessary parameters which lead to less electrode wear, better surface qual-
ity and high erosion rate according for the selected operation (finishing, roughing, etc.). It
is very clear to say that the developed system is particularly suitable for small and middle
size workshops that have conventional EDM machine tools. Skrabalak et al. (2004) pre-
sented the simplified model for estimation current of electrochemical dissolution and EDM
in the ECDM process. FL may help in reducing the number of micro cracks and surface
roughness parameter. Paper contains also simplified model of the control system used for
simulation.
3.2.3 Discussion
Machining processes consists of conventional machining process and modern machining

process. The definition of machining process has been given in Sect. 2.2. In term of con-
ventional machining process, milling process was mostly being investigated. For mod-
ern machining process, EDM has been successfully applied using FL. Figure 2 shows
the applications of FL in machining processes. Milling process has been investigated
by many researchers because among various machining processes, the milling process
is one of the most fundamental and commonly encountered material removal operations
occurring in a real manufacturing environment (Ho et al. 2009). EDM is more popular
because it has faster response and higher stability and more accurately model real-world
events by allowing the existence of uncertainty to simulate human reasoning (Shih and
Kao 2008). Based on the findings, it shows that FL is still relevant in modeling tech-
nique for both conventional and modern machining processes. The complexity of the
machining problems can be solved by using FL model which is adapted with the human
reasoning.
123
Fig. 3 Machining performances modeled with FL
3.3 Analysis of FL on machining performance
In machining processes, the machining performances are an indicator to describe the quality
of the manufactured product. The most common of machining parameters being investigated
by machinists are surface roughness, cutting force, material removal rate, tool-wear, flank-
wear, torque, electrode wear rate, tool-life, drilling time, machine utilization level, cutting
width, dross inclusion, short circuit ratio, white layer thickness, erosion rate, and control
voltage. Surface roughness was mostly being investigated based on review from previous
researchers. Surface roughness is formed as a result of the repetition of the cutting tool tip
moving along the work piece at the desired feed rate during machining processes. Surface
roughness is generally considered to be major factors affecting random relative vibration
between the tool and work piece (Lu 2008). Based on Fig. 3, surface roughness was mostly
being investigated followed by cutting force and material removal rate. Surface roughness was
mostly being investigated using FL because it is one of the important properties for evaluating
the work piece quality during the machining process. The important factor of milling process
in evaluating the quality of products is surface finish; and surface roughness is indicator
to determine the surface finish. It is means that when surface roughness is decreased, the
surface finish increased; hence the quality of products might be increased. Assigning good
combinations and numbers of FL rules are important role in order to obtain the desired output
values. Expertise needs to conduct ‘trial-and-error’ experiments in order to obtain good
combination values of machining performance in order to obtain machining performance
values. The precise logic of FL model dealt with the machining problems might reduce
the expertise time and decreased the operational cost for industrial sectors. There are some
previous researchers that dealt with FL to investigate one or more machining performance
on their experiments (Syn et al. 2011; Maji and Pratihar 2010; Nandi and Paulo Davim 2009;
Uros et al. 2009; Rao et al. 2009; Yuan et al. 2009; Caydas et al. 2009; Iqbal et al. 2007a;
Yilmaz et al. 2006; Nandi and Pratihar 2004; Lin et al. 2002; Zhang et al. 2002; Liao and Woo
2000; Lin et al. 2000; Biglari and Fang 1995). FL have been used to investigate one or more
machining performance because it able to conduct experiments concurrently using MATLAB
fuzzy logic toolbox in order to obtain the machining performance values. It can be assumed
as powerful technique due to ability in conducting multiple machining performances without
any constraints.
123
Fig. 4 Machining performance modeled with FL
Fig. 5 Membership function used in machining process
3.4 Analysis on defuzzification of FL used in machining process
The fuzzy outputs for all rules are aggregated to one fuzzy set. To obtain a crisp decision from
this fuzzy output, we have to defuzzifier the fuzzy set, or the set of singletons. Therefore, we
have to choose one representative value as the final output (Li 2012). In machining process,
the operator needs a single discrete valued direction. So it is required to select a single point
from fuzzy distribution that provides the best value. The process of reducing a fuzzy set
to a single point is known as defuzzification (Iqbal et al. 2005). There are several type of
defuzzification method; centroid, bisector, Mean of Maximum (mom), Largest of Maximum
(lom) and Smallest of Maximum (som). Figure 4 revealed that the most frequently use
of defuzzification is center of gravity (centroid). This method is the most prevalent and
physically most appealing of all the defuzzification methods (Babaesmailli et al. 2012). It
is because, centroid are computation intensive and there is no rigorous way to analyze them
except through experiment-based studies. Centroid was employed as defuzzification method
because it gave smoothly varying output of response variables for gradually varying input
values of machining parameters.
3.5 Analysis on membership function of FL used machining process
Membership function is a curve that defines how each point in the input space is mapped to
a membership value (or degree of membership) between 0 and 1. Triangular, Trapezoidal,
Gaussian, Bell-shaped and Polynomial are the types of membership function which have
been used by previous researchers. Figure 5 shows that triangular membership function was
mostly used by previous researchers. Triangular functions are commonly applied because of
123
their simplicity and because they are easy to implement in a computer program and they can
approximate most non-triangular ones (Kor et al. 2010). Trapezoidal and triangular member-
ship functions are common but unrealistic in their representation of an uncertainty because of
their sharp transitions compared to Gaussian membership functions which have the advantage
of being smooth (Syn et al. 2011). The membership functions are termed as fuzzification.
In membership functions, linguistic variables are expressed in the form of linguistic state-
ments such as low, medium, and high are used to represent the input and output of machining
processes numerical values. The performance of the FL-based approaches may be further
enhanced by either increasing the number of linguistic terms that represent the variables or
by using the non-linear membership function distributions. Therefore, the triangular mem-
bership function distributions may be replaced by some non-linear membership function
distributions for further improvement of the performance of the FL system (Vundavilli et
al. 2012). It is important to select non-linear membership function distribution in order to
enhance the performance of the FL based approaches. It is because; non-linear membership
function might give the best results of machining performance compared to linear member-
ship function. It is obvious due of the fact that inherent non-linearity of the process has been
better understood by the ANFIS model with non-linear membership functions compared to
that with the linear membership functions. Maji and Pratihar 2010 used ANFIS model with
the bell-shaped MF (non-linear MF), Triangular MF (linear MF) and statistical regression
analysis on their experiments. It shown that bell-shaped outperformes Triangular MF in the
term of average percent deviation in prediction of MRR and SR. There are some previous
researchers that has been applied one or more membership function method on their exper-
iment (Maji and Pratihar 2010; Nandi and Paulo Davim 2009; Uros et al. 2009; Yuan et al.
2009; Yan and Fang 2008; Jiao et al. 2004; Nandi and Pratihar 2004; Lo 2003; Zhang et
al. 2002; Lin et al. 2000; Peres et al. 1999). There are no problems to choose more than
one membership function in the experiments because the importance is how we select the
appropriate types of membership function.
4 Abilities, limitations and improvements of fuzzy logic in machining process
4.1 Abilities
Some ability of FL in modeling machining process may include:-
(i) The modeling technique has been successfully developed to predict machining per-
formances with excellent degree of accuracy. Consequently the researchers strongly
believes that ANFIS could be the best hybrid AI tool with the capability of data training
and rule setting which has to be further explored with critical consideration in producing
precise part of any material in the field of precision machining (Sivarao 2007).
(ii) FL has been enhanced to apply on majority research areas, especially dealing with
complexity and uncertainty (Syn et al. 2011).
(iii) The advantage is that a FL responds quickly to complex sensory inputs while the exe-
cuting speed of sophisticated control algorithms in a conventional controller is severely
limited (Zuperl et al. 2005). Current researchers have shown that FL has important
advantages over conventional controllers. The advantage is that a FL can efficiently uti-
lize a much larger amount of sensory information in planning and executing a control
action than ability of industrial controller.
123
(iv) FL does not require numerical precision. As the control conditions change it can be
tuned up simply according to new conditions.
(v) Most important advantage of FL based systems is its ability of performing simple,
cheap and fast solutions to control necessity by modeling human behavior even in case
of building a mathematical model is impossible (Yumak and Ertunc 2006).
4.2 Limitations
Some limitations of classic FL in modeling machining process could be stated as follow:

(i) The experiment conducted by Syn et al. (2011) that is applying FL in laser machining
process give conclusion that the limitations of the proposed fuzzy expert system is that
it cannot handle with new situations not bonded explicitly in its knowledge based (that
is, situations not fitting exactly those described in the IF parts of the rules).
(ii) In FL, rules and membership functions need to be determined by experts and they could
not be determined and adjusted automatically (Yumak and Ertunc 2006).
(iii) FL becomes difficult to gather knowledge of the process beforehand. To overcome this
difficulty, a method for automatic design of fuzzy knowledge base should develop in
future, using a Genetic Algorithm-based tuning. Thus, in future, the FL will be able to
predict the output more accurately for a set of input parameters. This ability of predicting
the output of a manufacturing process before carrying out the real experiment might be
useful to develop an expert system, which is required for an automatic manufacturing
system (Nandi and Pratihar 2004).
(iv) Biglari and Fang (1995) believed that fuzzy set theory is inadequate to give a solid
theoretical explanation when being used in the control of small-hole drilling operations.
It is difficult to prove if the knowledge rules developed are optimal instead of the
experimental result was shown very good performance with stable results.
(v) Too many linguistic rules are used by machining specialists while many of them are
redundant. These unnecessary rules complex the knowledge base and then the modeling
process (Mahdavinejad 2008).
4.3 Improvements
The limitations discussed in previous section could be classified into two groups. The first
group (i), (ii), and (iii) are mostly concerned with accuracy of FL and the second group (iv)
and (v) are mostly concerned with interpretability of FL. Therefore, there are two regular
types of modifications in FL to overcome these limitations.
4.3.1 Improving the accuracy of FL
There are some proposals for enhancing the FL accuracy by extending the regular linguistic
model of FL and making it more flexible (Casillas et al. 2003) specially in handling with
new situations not bonded explicitly in its knowledge based. Two major possibilities are
highlighted as follows.
(a) Applying linguistic modifiers
Linguistic modifiers proposed by Zadeh (1973) is an operator to allocate membership func-
tions for fuzzy sets related to the linguistic terms by assigning more or less clarity, such as
123
“very high” (Casillas et al. 2003; Dvorak 1999; Gonzalez and Perez 1999). The membership
functions could be defined by using experts’ knowledge or by training which is an effective
way for determining linguistic modifiers (Alcalá et al. 2005; Lu 2008). GA is an effective
training algorithm for finding optimal type and strength of the linguistic modifiers and is
successfully utilized by previous researchers (Casillas et al. 2005; Alcalá et al. 2005; Nuovo
and Catania 2006). Although using the modifiers could increase the accuracy of FL, but
they have not been previously applied by researchers for modeling the machining processes.
Therefore, employing this approach and an effective training algorithm to find optimal para-
meters for membership functions will improve the accuracy of FL in modeling machining
processes.
(b) Applying weighted rules
This improvement involves employing an additional parameter for each rule indicating its
importance rank in modeling process. Consequently, this modified FL increases the flexibility
and model performance (Casillas et al. 2003). Theses weights are regularly utilized to handle
instabilities with advanced inference methods or neural networks. Furthermore automatic
training of weights is possible by using evolutionary optimization algorithms to obtained
optimal rules in different situation of machining process. GA and PSO are the most well-
known optimization algorithms employed lucratively to enhance the model accuracy (Alcalá
et al. 2005). Nandi and Pratihar (2004) proposed an optimization algorithm based on GA to
automatically design fuzzy rules in machining process. In addition, Krishna et al. (2009) and
Wang et al. (2003) are some researches which applied GA successfully as training algorithm
of FL to increase accuracy of the modeling in machining processes. In addition, Chen et al.
(2012) proved that PSO could outperform GA in the terms of accuracy of the model and
computational time.
4.3.2 Improving the interpretability of FL
This enhancement is typically obtained by reducing the complexity of the FL model

(Casillas et al. 2003). Optimal selection of significant fuzzy rules is an important factor
for this purpose which is widely utilized by previous researchers in the recent years. A
fitting subset of fuzzy rules could be selected by employing different training algorithms
such as orthogonal least squares (Wang and Mendel 1992); singular value decomposition
(Mouzouris and Mendel 1997; Nariman-Zadeh et al. 2005); and table look-up scheme to
extract fuzzy rules (Lou et al., 1999). However, the division of the input and output spaces,
and membership functions of the fuzzy sets defined in the spaces, must be determined by
experts ahead, and no optimization is carried out (Lou et al., 1999). In contrast, evolutionary
optimization algorithms such as GA could be employed to enhance the interpretability if FL.
Wong and Hamouda (2000) proposed a GA algorithm to find optimal subset of fuzzy rules.
Also, Wei and Cheng (2012), Tan et al. (2012) and Chen et al. (2012) are some of the recent
researches which proposed GA algorithm to optimize fuzzy rules for semi expert judgment
automation.
On the other hand, selecting an appropriate type of fuzzy rules could improve the accuracy
of FL. Nandi and Paulo Davim (2009) proved that applying TSK type of fuzzy rules could
provides better prediction of multi performances on machining processes specially drilling
process compared to the usual fuzzy rules.
123
5 Summaries and future work
Based on five type of analysis conducted, the analysis on the purpose of FL shows that FL
has been used in prediction; in machining process the analysis shows that milling process
contributes the biggest number that applied FL; analysis machining performances shows
that surface roughness contributes the highest machining performance studied using FL;
analysis on defuzzification shows that center of gravity (centroid) method is mostly used to
perform defuzzification; and lastly analysis on membership function shows that triangular
was mostly applied by the researchers for performance measurement. Papers from 2000
till 2012 that has been reviewed revealed, FL has been extensively used in application in
modeling of machining process. The evolution FL is rapidly increase time by time but its
application (prediction, selection, monitoring, control and optimization) still in the same
domain (machining).
Therefore, works on the usage of FL is still relevant in this decade even though the
emergence of new AI technique such as SA, PSO, ACO, and ABC will replace or as
an alternative of FL. Combination of two or more branches of AI technique is called
hybrid system has been applied rapidly in machining process. ANFIS actually is a com-
bination of ANN and FL. ANFIS is one of the hybrid system which successfully and
mostly being used by researchers because this method is an extension from the FL in
order to make the improvement of the FL technique. Application of a well-established
evolutionary algorithm with FL can be greatest combination and might give good agree-
ment for the better results in machining problems. Therefore, for the future works, FL
have potentially used in the prediction of machining performance in milling and abra-
sive water jet machining process. It is because, machining performance like depth of cut
and surface roughness for both machining process needs to be investigated more since
there are very significance in industrial needs in order to obtain desired product. FL might
give a good agreement with the combination of other evolutionary technique (SA, PSO
or ACO) in order to enhance the result of predicted values which called as optimization
techniques. Optimization might produce a better results compared to predicted results.
Other possible techniques could be combined with FL are fuzzy particle swarm intelli-
gence (FPSO) algorithm (Yang et al. 2011a; Zhao et al. 2010; Kor et al. 2010), fuzzy sup-
port vector machine (FSVM) algorithm (Cheng et al. 2012; Anifowose and Abdulraheem
2011; Brezak et al. 2012) and fuzzy logic combined with regression analysis (Kovac et al.
2012).
Here is some of the previous work that has been investigated in order to improve the
FL technique for the future work. There are some issues need to be investigated as men-
tioned by Dong and Wang (2011), on how to find a better architecture of ANFIS (includ-
ing the number of rules and the type of membership function) and how to improve the
predictive performance using ANFIS. The researcher believes that, the hybrid intelligence
can be further critically explored for controlling and optimizing techniques of any machin-
ing process with high number of controllable parameters (Sivarao 2007). The future target
of research is to include the optimization of other milling parameters like cutting speed,
feed, depth of cut, tool tilt angle and more in the configuration of the expert system
(Iqbal et al. 2007a). Non-traditional laser machining, was used in the modeling investi-
gation as this machining process requires controlling of more than seven critical parame-
ters and to date, no researchers has used ANFIS to model this exact phenomenon (Sivarao
2007).
This review paper has presented the successfully use of FL technique for machining
processes in order to resolve modeling either in conventional or modern machining process.
123
In order to get the information either journal paper or conference paper, the institute (UTM)
have subscribed several website indexed or non-indexed journal/conference such as Institute
of Electrical and Electronics Engineers (IEEE Xplore), ScienceDirect, SciVerse, Scopus,
Elsevier, Thomson Reuters, SpringerLink, Taylor and Francis, and SAGE journal online.
For the future work, this paper can be extended by refers to other paid website such as, IOP,
InderScience, Paramount, and DLINE.
Acknowledgments The authors greatly acknowledge the Research Management Centre, UTM and Ministry
of Higher Education (MoHE) for financial support through the Exploratory Research Grant Scheme (ERGS)
Vot. No. J13000078284L003.
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Fuzzy Logic For Modeling Machining Process

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Artif Intell Rev

Fuzzy logic for modeling machining process: a review

M. R. H. Mohd Adnan · Arezoo Sarkheyli ·

© Springer Science+Business Media Dordrecht 2013

Abstract The application of artificial intelligence (AI) techniques in modeling of machin-

Keywords Artificial intelligence · Fuzzy logic · Machining process · Machining parameter

M. R. H. Mohd Adnan (B) · A. Sarkheyli · A. Mohd Zain · H. Haron

2 Overview of fuzzy logic and machining process

2.1 Fuzzy logic

2.2 Machining process

3 Analysis on the application of fuzzy logic for modeling machining process

This section is focusing on the purpose of FL in modeling of machining process, followed by

3.1 The purpose of fuzzy logic in modeling of machining process

3.2.1 Conventional machining process

Conventional machining is generally regarded as using manually controlled machines. The

zoidal depth of cut force flank with small

modeling and prediction

(2009) distance, roughness that the ability to predict

Fig. 1 Purpose of machining model using FL

3.2.2 Modern machining process

Fig. 2 Machining processes dealt with fuzzy logic

Machining processes consists of conventional machining process and modern machining

Fig. 3 Machining performances modeled with FL

3.3 Analysis of FL on machining performance

Fig. 4 Machining performance modeled with FL

Fig. 5 Membership function used in machining process

3.4 Analysis on defuzzification of FL used in machining process

3.5 Analysis on membership function of FL used machining process

4 Abilities, limitations and improvements of fuzzy logic in machining process

Some ability of FL in modeling machining process may include:-

Some limitations of classic FL in modeling machining process could be stated as follow:

4.3.1 Improving the accuracy of FL

(b) Applying weighted rules

4.3.2 Improving the interpretability of FL

This enhancement is typically obtained by reducing the complexity of the FL model

5 Summaries and future work

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