Optimization by Grey relational analysis of EDM parameters on machining Al–10%SiCP composites

Optimization of process parameters is the key step in the Taguchi methods to achieve high quality without cost inflation. Optimization of multiple response characteristics is more complex compared to optimization of single performance characteristics. The multi-response optimization of the process parameters viz., metal removal rate (MRR), tool wear rate (TWR), taper (T), radial overcut (ROC), and surface roughness (SR) on electric discharge machining (EDM) of Al–10%SiCP as cast metal matrix composites using orthogonal array (OA) with Grey relational analysis is reported. The optimization of the process was performed in the following steps: (a) Normalizing the experimental results of MRR, TWR, T, ROC, and SR for all the trials. (b) Performing the Grey relational generating and to calculate the Grey relational coefficient. (c) Calculating the Grey relational grade by averaging the Grey relational coefficient. (d) Performing statistical analysis of variance (ANOVA) for the input parameters with the Grey relational grade and to find which parameter significantly affects the process. (e) Selecting the optimal levels of process parameters. (e) Conduct confirmation experiment and verify the optimal process parameters setting.