Micro-machining and process optimization of ultrasonic assisted rotary µ-electrochemical discharge machining using TOPSIS method

Abstract

Glass is a substance that is gaining numerous applications in many industries, such as biomedical, nuclear, etc., due to its hard, transparent, and inert nature. The main challenge is to machine glass due to its brittle nature. Electrochemical Discharge Machining (ECDM) is a novel process that is being used to machine such hard and electrically non-conductive materials. Over the years, researchers tried to incorporate many other processes into the ECDM process in order to increase the process capabilities. In this research, Ultrasonic assisted Rotary µ- ECDM process was used to drill holes in glass workpiece. In this process, the rotary motion was provided to the workpiece rather than to the tool to observe the results of this process. Experiments were performed using Taguchi’s L9 orthogonal array taking amplitude of vibrations, rotational speed, and tool feed rate as the input parameters and overcut and circularity as the response characteristics. In addition to this, multi-response process optimization was carried out using TOPSIS (Technique for Order Preference by Similarity to Ideal Solution) method to optimize the process.