Optimization of process parameters in ultrasonic machining using integrated AHP-TOPSIS method

Abstract

The process by virtue of which holes and cavities are formed in a metal work piece with the help of shaped tools, high frequency mechanical motion and abrasive slurry is known as Ultrasonic Machining Process. Its working principle is completely different from the other traditional machining processes such as laser beam machining and electrical discharge devices. This is developed machine removal processes in which the work material is less damaged by the thermal energy and it also introduce significant level of residual stress which is important for survival of the work material. This character of the process makes USM more enhanced and better machine job characteristics. This characteristic is also required for determining the optimal control parameter settings of an USM process’s is a non-traditional machining process in which abrasive content in slurry are driven against work by tool oscillating at low amplitude and high frequency. In this research paper stainless steel is used as tool material in the whole process and zirconia bio ceramic plate is taken as a work piece material. The process parameters are considered as feed rate, slurry concentration, power rating and grit size. Through this work, it is found that responses highly correlated with correlation coefficient, which justifies the application of MCDM as an optimization tool. The optimization studies are carried out on an ultrasonic machining process with multi response characteristics depend on the multi criteria decision making methodology (MCDM), using technique for order preference by similarity to ideal solution (AHP-TOPSIS) approach are described in this paper. The final results of this paper indicate the effectiveness of USM using MCDM method for different USM parameters to produce high quality parts made of zirconia Bio-ceramics with excellent productivity.