Multi objective optimization of ECG process under fuzzy environment

Purpose - In the present research work electrochemical grinding (ECG) process is applied to machine Al2O3/Al interpenetrating phase composite. The purpose of this paper is to present a new approach to optimize the ECG process parameters while machining alumina-aluminum (Al2O3 - Al) interpenetrating phase composites (IPC) used in automotive, aircraft and manufacture of space ships applying Taguchi-based experimental studies and fuzzy multi-criteria decision-making techniques. Design/methodology/approach - The present work identifies the process variables that have significant consequences during ECG of Al2O3/Al IPC. The Taguchi L-9 orthogonal array is selected for design of experiments and the analysis is carried out following signal to noise ratio. The analysis of variance is carried out to establish the factors that significantly influence the responses. The present work also investigates the multi objective optimization of ECG process parameters using VIseKriterijumsa Optimizacija I Kompromisno Resenje (VIKOR) and Grey relational analysis (GRA) to establish the reference ranking from a set of alternatives in the presence of conflicting criteria. Findings - Material removal rate, surface finish, overcut and cutting force are shown to depend on the type of electrolyte, supply voltage, depth of cut and electrolyte flow rate. It is found that voltage and electrolyte concentration are important. The optimal machining parameter combination for ECG process is determined using fuzzy set theory, VIKOR and GRA. Substantial improvement in machining performance takes place. Practical implications - A variety of manufacturing techniques are available for processing of Al2O3 - Al metal matrix composites. Generally manufacturers favor low cost modus operandi. Therefore ECG process is the best alternative for processing of MMCs in the present commercial sectors. The experimental investigation approach can act as useful and an efficient guideline for manufacturing. Originality/value - The characteristic features of the ECG process are reflected through Taguchi design-based experimental studies with various process parametric combinations. Application of multi-response optimization technique for evaluation of best parametric combination for machining Al2O3 - Al IPC material using ECG process is a first-of-its-kind approach in literature.