Multi-Objective Optimization of Hole Drilling Electrical Discharge Micromachining Process Using Grey Relational Analysis
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Multi-Objective Optimization of Hole Drilling Electrical Discharge Micromachining Process Using Grey Relational Analysis Coupled with Principal Component Analysis R. K. Porwal • V. Yadava • J. Ramkumar
Received: 7 September 2012 / Accepted: 2 September 2013 / Published online: 22 November 2013 Ó The Institution of Engineers (India) 2013
Abstract Optimization of performance characteristics and quality characteristics during hole drilling-electrical discharge micromachining (HD-EDMM) is necessarily multi-objective in nature and needs considerable attention for finding preferred operating values and levels for a desired output responses. A hybrid method comprising of grey relational analysis (GRA) coupled with principal component analysis (PCA) is used in this paper for the determination of preferred combination of input parameters of HD-EDMM for maximization of material removal rate and minimization of other three output parameters such as tool wear rate, hole taper and hole overcut simultaneously. The micromachining parameters used are gap voltage at six levels, capacitance of capacitor at three levels and spindle speed at three levels. Eighteen sets of experiments are conducted as per L18 orthogonal array and GRA coupled with PCA is used for finding optimal parameter combination of the HD-EDMM process. Optimal combination of the process parameters for the multi-performance characteristics of the HD-EDMM has been found as gap voltage 140 V, capacitance of capacitor 10 nF, and 110 rpm of tool electrode.
R. K. Porwal V. Yadava (&) Department of Mechanical Engineering, Motilal Nehru National Institute of Technology, Allahabad 211 004, UP, India e-mail: [email protected] R. K. Porwal e-mail: [email protected]; [email protected] J. Ramkumar Department of Mechanical Engineering, Indian Institute of Technology, Kanpur, India e-mail: [email protected]
Keywords Hole drilling electrical discharge micromachining (HD-EDMM) Taguchi methodology (TM) Multi-objective optimization (MOO) Grey relational analysis (GRA) Principal component analysis (PCA)
Introduction In recent time the manufacturing industries involved with manufacturing of micro components or products are becoming increasingly attractive and important. They are capable to produce miniature products with diversified functional characteristics. Under these circumstances, the development of micromanufacturing processes becomes a need of today. Micromachining is a kind of micromanufacturing process used to create a micro feature in size few to hundreds of micron by selective controlled removal of excess material. Micromachining processes can be further classified as conventional micromachining and unconventional micromachining processes. Conventional micromachining are characterized by mechanical interaction of a sharp and well defined geometry tool with the workpiece such as micromilling, microturning, etc. Unconventional micromachining does not employ a conventional tool for material removal. Instead, they directly utiliz
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