Hybrid approach for parametric optimization of wire-electrochemical spark micromachining of borosilicate glass

Abstract

This work intends to implement a hybrid strategy for the multiobjective optimization of a wire-electrochemical spark micromachining (WECSMM) process, integrating the Taguchi technique and response surface approach. Initially, the optimum level of process variables, such as, thickness of workpiece, feed velocity of wire, concentration of electrolyte, and applied voltage, are evaluated using the characteristic loss function of Taguchi. After the process variables are optimized, the response surface model is built and refined using the central values that represent the best values. An experimental plan for borosilicate glass slicing was carried out during WECSMM, utilizing the L₉ Taguchi design process. For simultaneous optimization, the two attribute criteria like surface roughness (R_a) and material removal rate (MRR) have been chosen. When comparing the outcomes of a single strategy with the hybrid approach, the results demonstrate a significant increase in both quality aspects. As contrasted to Taguchi Methodology (TM), the couple approach was shown to increase MRR by 192% and lower R_a by 10%, respectively.