Roundness is one of the most common features in machining. The minimum zone tolerance (MZT) approach provides the minimum roundness error, i.e. the minimum distance between the two concentric reference circles containing the acquired profile; more accurate form error estimation results in less false part rejections. MZT is still an open problem and is approached here by a Genetic Algorithm. Only few authors have addressed the definition of the search space center and size and its relationship with the dataset size, which greatly influence the inspection time for the profile measurement and the convergence speed of the roundness estimation algorithm for a given target accuracy. Experimental tests on certified roundness profiles, using the profile centroid as the search space center, have shown that the search space size is related to the number of dataset points and an optimum exists, which provides a computation time reduction up to an order of magnitude.

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