Title: Multi-response optimisation of electrochemical machining process parameters by harmony search-desirability function optimiser

Authors: M. Kalaimathi; G. Venkatachalam; M. Sivakumar; S. Ayyappan

Addresses: School of Mechanical and Building Sciences, VIT University, Vellore-632014, Tamilnadu, India ' School of Mechanical and Building Sciences, VIT University, Vellore-632014, Tamilnadu, India ' Department of Mechanical Engineering, Sree Sowdambika College of Engineering, Aruppukkottai-626134, Tamilnadu, India ' Department of Mechanical Engineering, Government College of Engineering, Salem-636011, Tamilnadu, India

Abstract: Selection of the optimum electrochemical machining (ECM) process parameters is extremely crucial as this machining process involves huge capital investment and operating cost. In this work, the harmony search (HS) algorithm is integrated with desirability function (DF) in such a way that new HS-DF optimiser is proposed to optimise the ECM process parameters. The influence of three predominant ECM process parameters i.e. inter-electrode gap (IEG), voltage (V) and electrolyte concentration (EC) on the performance measures of material removal rate (MRR) and surface roughness (Ra) was considered. The optimised values of EC = 115 g/l, V = 13 V, and IEG = 0.11 mm resulted in MRR of 0.726 g/min and Ra of 1.53 μm for electrochemical machining of Monel 400 alloys. The optimised results are compared with those drawn from the past research and found better. The HS-DF optimiser proves its applicability and suitability for optimising process parameters of ECM process, which reduces considerable computational, experimental cost and time.

Keywords: electrochemical machining; ECM; multi-response optimisation; harmony search; HS; algorithm; desirability function; DF.

DOI: 10.1504/IJMTM.2020.108017

International Journal of Manufacturing Technology and Management, 2020 Vol.34 No.4, pp.331 - 348

Received: 14 Dec 2015
Accepted: 10 Aug 2016

Published online: 11 Apr 2020 *

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