Optimization of process parameters in micro electrochemical machining using TOPSIS technique with Analytical Hierarchy Process (AHP)

Abstract

Electro-chemical machining (ECM) is one of the extensively used unconventional machining processes employed in industries to machine difficult-to-machine materials such as super alloys, titanium alloys, stainless steel, etc. It does not impart any mechanical stresses on the workpiece. The primary requirement of the work material used in this process should be electrically conductive materials. In favour of these characteristics, Hastelloy C276 is used as a work material because it exhibits excellent physical properties over cast iron. Generally, the quality of machining mostly relies on the electrolyte (mmol/L), feed rate (mm/rev), and duty ratio. These credential parameters are considered in this present work to enhance the machining quality, such as circularity, taper angle, and metal removal rate (MRR). The Taguchi L9 orthogonal array is used to learn machining behaviour under various circumstances. And this time, an Analytic Hierarchy Process (AHP) is used to allocate the weight for each response in the TOPSIS multi-criteria decision-making method. According to the findings, sodium nitrate (NaNo3) has a higher metal removal rate than sodium chloride (NaCl) and sodium bromide (NaBr). It will, however, result in a low-quality hole. The taper angle is inversely proportional to the feed rate.