Multi-response Optimization of Process Parameter of Spark Erosion Electric Discharge Machining Using Principal Component Analysis Coupled with TOPSIS

Abstract

Electric Discharge Machining (EDM) is a thermo-electric non-traditional machining process in which material removal takes place through the process of controlled spark generation between a pair of electrodes submerged in a dielectric fluid. Due to difficulty in the availability of EDM, it is very complicated to determine optimal process parameters for improving performance. Therefore, optimization of process parameters is an important action in machining, especially for nontraditional machining procedures like EDM. Due to wide range proper selection of process parameters for the EDM process it heavily depends on the operator’s technologies and experience. The Machining parameters cannot meet the operator’s requirements which are given by the machine tool manufacturer. Therefore they are not able to give the optimal conditions. To solve this problem multi-response optimization technique of principal component analysis coupled with TOPSIS are used to determine the optimal machining parameters in spark erosion electric discharge machine. To conduct the experiments die steel is taken as material of the work piece and copper is taken as the material of electrode. In this present work input parameters such as current, voltage, pulse on time and pulse off time considered as a control variable and performance characteristics surface finish (Ra), material removal rate (MRR) and tool wear rate (TWR) have been studied to get the optimal machining parameters. Here for four control factors and four level, L16 orthogonal array was used for experimental run. Finally the confirmation test is carried out to check the validity of optimization technique.