Modeling and Response Optimization of Traveling Wire Electro-Chemical Spark Machining of Borosilicate Glass Using Hybrid Approach
Basanta Kumar Bhuyan, Pravabati Bhuyan, Satish Mishra
Abstract
Traveling Wire Electro-Chemical Spark Machining (TW-ECSM) process is a new innovative thermal erosion-based machining process suitable for cutting electrically nonconductive materials using tool electrode in the form of wire. This article attempts experimental modeling of TW-ECSM process using a hybrid methodology comprising Taguchi methodology (TM) and response surface methodology (RSM). The experiments were carried out on borosilicate glass using L[Formula: see text] orthogonal array (OA) considering the input parameters like applied voltage, pulse on-time, pulse off-time, electrolyte concentration and wire feed velocity along with process performances such as material removal rate (MRR), surface roughness (R[Formula: see text] and kerf width (K[Formula: see text]. The interaction influence of input parameters on process performances was also discussed. Further, multi-objective optimization (MOO) of response performances of TW-ECSM process is executed using a coupled approach of grey relational analysis (GRA) and principal component analysis (PCA). The optimal process parameter setting illustrates the improvement of MRR by 171%, diminution of R a and K[Formula: see text] by 27% and 8% against the initial parameter settings. Moreover, irregular cutting of kerf width and surface characteristics were also scrutinized using scanning electron microscope (SEM).