Multi-performance modeling and optimization control strategies for electro-chemical honing: a critical evaluation

Abstract

Electro-chemical honing (ECH) is a hybrid electrolytic precision micro-finishing technology that integrates physicochemical actions of the electro-chemical machining and conventional honing processes to provide controlled functional surface-generation and fast material removal capabilities in a single operation. Three different strategies, namely the utility-based Taguchi approach, Taguchi–RBFNN–DF–GA strategy and GA-tuned fuzzy Taguchi inference application, have been recently reported by the author for multi-performance modeling and optimization control ECH process. In this work a critical evaluation of their prospective features, strengths and weaknesses has been done for benefit of the user and research fraternity. The methodologies have been demonstrated using a case study of multi-performance modeling and optimization control ECH, involving three performance criteria. Results indicate that all three techniques are well suited to the complex manufacturing processes that involve several correlated variables with vaguely defined parametric relationships like in ECH. It was also found that the predicted optimal results are sensitive to the way the factorial interactions are treated. The actual experimental results at the optimal parametric conditions predicted using the three approaches are quite close.