Multi-Response Optimization of Vibration Assisted Electrical Discharge Drilling Process using PCA based GRA approach

Nowadays, quality and cost of the product are the key issues for the industries to sustain in the global market. Manufacturing industries related such as aerospace, defense and automobile, are highly concerned with the aesthetic aspect and high-quality finishing of products. In order to that, industries are looking for the development of advanced technology and also concentrating on optimizing the production. The utility of advanced engineering materials viz. super-alloys and metal matrix composite (MMC) materials are increased day by day due to improved mechanical properties. In view of the above-mentioned problem, Hybrid machining processes are becoming the best possible solution for improving the MRR and surface finish. In present research, a hybrid approach of Vibration Assisted Electrical Discharge Drilling (VA-EDD) is used for processing of Al-TiB2. TiB2 is a hard material with good strength and wear resistance at elevated temperature being used in advanced metal cutting industries for ceramic cutting tool, TiB2 coated tools etc. This paper presents a multi-response optimization of the VA-EDD process for Al-TiB2 composite material to provide higher MRR with a good surface finish. The experiments were conducted using a face-centered central composite design (CCD) of response surface methodology (RSM). The machining characteristics, MRR and SR have been optimized simultaneously by using Principal Component Analysis (PCA) based Grey Relational Analysis (GRA). The VA-EDD process was optimized for getting the optimal levels of process parameter for higher MRR and lower R-a value. The results reveal that the PCA based GRA approach have acquired the setting of optimal process parameters for the VA-EDD process as pulse current (I-p) = 12A, pulse on time (T-on) = 90 mu s, pulse off time (T-off) = 15 us, tool rotation (rpm) = 1100 rpm, and vibration amplitude = 4 mu m. The quality of machined surface has also been examined by scanning electron microscope. (C) 2019 Elsevier Ltd. All rights reserved.