Abstract
ABSTRACT Current study investigates the efficacy of electrochemical micro-drilling (ECMD) process during micro-hole fabrication on a Ti6Al4V alloy sheet of 1.2 mm thickness using a cylindrical-shaped micro-tool. Ethylene glycol-based electrolyte was selected to overcome excessive passivation. Experiments were conducted by altering voltage, feed rate (FR), and electrolyte concentration (EC) using a central-composite-design to observe their effects on the output parameters. The desired response parameters, such as radial overcut (ROC), and taper were examined while fabricating dimensionally accurate micro-holes including the volume removal rate (VRR) that occurred during the process. ANOVA results established voltage as the major significant input parameter that affects all the responses, followed by FR. In addition, different nature-inspired optimization techniques, namely Multi-Objective Grey-Wolf Optimizer (MOGWO), Multi-Objective Bonobo Optimizer (MOBO), and Multi-Objective Particle Swarm Optimization (MOPSO), were employed. MOBO reported the best Pareto-surface in terms of uniformity and spread measures and suggested a FR of 0.3 μm/s for optimal micro-drilling operations.
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