Abstract
The present work proposes the multiple response optimization of ultrasonic assisted electric discharge machining (UAEDM) process through Taguchi-grey relational analysis (TGRA) approach, during machining of Nimonic 75 superalloy. Nimonic 75 finds its vast applications in aerospace, nuclear, chemical industry, notably in highly corrosive and oxidizing environments. Three response variable namely material removal rate (MRR), surface finish (SF) and tool wear rate (TWR) were optimized. Based on the average responses computed from Taguchi-grey relational analysis, the tool electrode material-copper, gap current of 12 A, discharge voltage of 45 V, pulse on duration of 200 µs, pulse off duration of 15 µs and tool lift time of 2 sec were estimated as optimal parametric settings for UAEDM process. Predicted results have been verified by conducting confirmation experiments indicating an overall improvement 2.02% on MRR, 5.74% on SF and a reduction of 3.98% on TWR.
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