Abstract
Previously, some authors proposed the innovative Taguchi–ABC and Taguchi–Pareto optimization tools to concurrently optimize and prioritize processes. In this paper, the models were used to optimize the electrical discharge machining (EDM) process parameters of AA6061/10%Al2O3 AMMC, validated with published data. Besides, the analytical hierarchy process (AHP) was used to determine the weight of factors. The Taguchi–Pareto 80/20 method utilizes the smaller-the-better quality attribute and a complimentary effort of the analysis of variance. The Taguchi-ABC uses the classified A, B and C schemes to prioritize the parameters. The AHP ranks the system as sub-problems of the top-level objective hierarchy followed by lower-level sub-criteria and bottom level variables. The results show the decreasing order of factors (pulse-on-time > peak current > duty factor) for Taguchi analysis and Taguchi-Pareto. The later yielded the optimal parametric setting of A1B2C2, indicating peak current of 6 amps, pulse-on-time of zero and duty factor of 0.6. The Taguchi-ABC reduced to Taguchi AB (i.e. optimal parametric setting as A1 B2) whereby the C (duty factor) yielded lower delta value than B (pulse-on-time). The AHP offered a conflicting result with duty factor having the largest criteria weight and the order of the weights of the factors is duty factor > pulse-on-time > peak current. The consistency ratio was 0.07 > 0.1. The results would aid EDM process engineers to effectively manage the EDM process.
Highlights
The electrical discharge machining (EDM) does not take in consideration parametric optimization in concurrence with prioritisation of factors and equal importance is given to the process factors (Dey et al, 2017; Gangil and Pradhan, 2017; Dey et al, 2018; Kandpal et al, 2018; Gudipudi et al, 2019; Kim et al, 2018; Zhang et al, 2019; Gore and Patil 2018)
At present, despite the EDM process being saturated with various optimization studies, investigations on EDM of AA6061/10%Al2O3 are still at their infancy and no study has considered the concurrent optimization with the prioritization of factors (Kandpal et al, 2017; Kandpal et al, 2018)
The following points are taken from the study: The application of Taguchi–Pareto and Taguchi–ABC is valid for the EDM process and sensible results obtained that prioritized the factors The Taguchi–Pareto ranked the process parameters in the order of importance at pulseon-time > peak current > duty factor The Taguchi–ABC, which reduced to two factors B (Pulse-on-time) and C (Duty factor) ranked the parameters as duty factor > pulse-on-time The analytical hierarchy process ranked the parameters as duty factor (0.6651) > pulseon-time (0.2311) > peak current (0.1038) Using the AHP, the consistency ratio (0.07) is less than 1, and the new approach of AHP, which is used to complement the prioritization by Taguchi–Pareto and Taguchi– ABC
Summary
The electrical discharge machining (EDM) does not take in consideration parametric optimization in concurrence with prioritisation of factors and equal importance is given to the process factors (Dey et al, 2017; Gangil and Pradhan, 2017; Dey et al, 2018; Kandpal et al, 2018; Gudipudi et al, 2019; Kim et al, 2018; Zhang et al, 2019; Gore and Patil 2018) This opinion may yield redundant allocation of scarce EDM process resources and may sometimes deny legitimate factors of the needed resources despite the danger of system failure that threatens the EDM process (Siegel, 1965; Klocke et al, 2016). In any of the available studies, there is no report on
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