Optimization of process plans using a constraint-based tabu search approach

A computer-aided process planning system should ideally generate and optimize process plans to ensure the application of good manufacturing practices and maintain the consistency of the desired functional specifications of a part during its production processes. Crucial processes, such as selecting machining resources, determining set-up plans and sequencing operations of a part should be considered simultaneously to achieve global optimal solutions. In this paper, these processes are integrated and modelled as a constraint-based optimization problem, and a tabu search-based approach is proposed to solve it effectively. In the optimization model, costs of the utilized machines and cutting tools, machine changes, tool changes, set-ups and departure from good manufacturing practices (penalty function) are the optimization evaluation criteria. Precedence constraints from the geometric and manufacturing interactions between features and their related operations in a part are defined and classified according to their effects on the plan feasibility and processing quality.