Optimization of Process Parameters in Micro-Electrochemical Discharge Machining by Using Grey Relational Analysis

Abstract

Micro-electrochemical discharge machining is hybrid machining process which is based on combined principle of electro discharge machining and electro chemical machining. It is suitable for machining of both conductive as well as non-conductive materials. In this study a micro hole drilled on Ti-6Al-4V as work piece by varying machining parameters like electrolyte concentration, voltage and duty factor at three different levels. Orthogonal array L9 considered for design and performing experiments. The Grey relation analysis (GRA) was performed to optimize the output parameters i.e. material removal rate (MRR) and hole tapper angle (HTA). The result reveals that voltage was the most significant factor for both MRR and HTA followed by electrolyte concentration and duty factor. The maximum MRR and minimum taper angle are 1.50 mg/min and 0.98 ° obtained respectively. The GRA show optimal machining parameters at electrolyte concentration 3M, voltage 40 V and duty factor 25% respectively.