Skip to main content
SpringerLink
Log in

PCA based hybrid Taguchi philosophy for optimization of multiple responses in EDM

  • Published:
Sādhanā Aims and scope Submit manuscript

Abstract

The present study is aimed at a multi-response optimization problem by applying Principal Component Analysis (PCA) combined with Taguchi method. The investigation has been carried out through a case study in Electric Discharge Machining (EDM) of D2 steel by using copper, brass and Direct Metal Laser Sintered (DMLS) electrode produced by direct metal laser sintering using Directmetal20. The research work has been carried out to evaluate the best parametric combination which could fulfill multiple responses like lower Tool Wear Rate (TWR), higher Material Removal Rate (MRR) and lower Surface Roughness (Ra). Unlike the use of single-objective optimization problem in traditional Taguchi method, a hybrid Taguchi method has been developed in combination with PCA to solve multi-objective problem. Taguchi method assumes that the quality characteristics should be uncorrelated or independent which is not always fulfilled in actual condition. PCA is applied to remove response correlation and to calculate independent (uncorrelated) quality indices known as principal components. These principal components combined with weighted principal component analysis (WPCA) are used to calculate overall quality index denoted as Multi-response Performance Index (MPI). This investigation combines WPCA and Taguchi method for forecasting optimal setting. The predicted result by this method was validated through confirmatory test proving the efficacy of the process. Out of five input process parameters considered, tool electrode has been found to be the most significant factors through the Analysis of Variance (ANOVA).

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Figure 1
Figure 2

Similar content being viewed by others

References

  1. Rosochowski A and Matuszak A 2000 Rapid tooling: the state of the art. J. Mater. Process. Technol. 106: 191–198

    Article  Google Scholar 

  2. Kruth J P 1991 Material increase manufacturing by rapid prototyping techniques. CIRP Annals Manuf. Technol. 40(2): 603–614

    Article  Google Scholar 

  3. Liu X Y and Jiang J 2003 Environmental effects on the dimensions of SL5195 resin. Rapid Proto. J. 9(2): 88–94

    Article  Google Scholar 

  4. Greul M, Pintat T and Greulich M 1995 Tool production via fused deposition modelling via electoplating. In: Proceedings of the 4th European Conference on Rapid Prototyping and Manufacturing, pp. 227–283

  5. Ippolito R, Luliano L and Gatto A 1996 EDM tooling by solid freeform fabrication & electroplating technique. In: Proceedings of solid free form fabrication symposium. The University of Texas, Austin, pp. 199–206

  6. Rennie A E W, Bocking C E and Bennett G R 2001 Electroforming of rapid prototyping mandrels for electro-discharge machining electrodes. J. Mater. Process Technol. 110: 186–196

    Article  Google Scholar 

  7. Semon G 1975 A Practical Guide to Electro-Discharge Machining. 2nd ed., Geneva Ateliers des Charmilles

  8. Dickens P M and Smith P J 1992 Stereo lithography tooling. In: Proceedings of the 1st European Conference on Rapid Prototyping and Manufacturing. Nottingham, UK, pp. 309–317

  9. Arthur A and Dickens P M 1995 Rapid prototyping of EDM electrodes by stereo lithography. In: Proceedings of the International Symposium for Electro Machining (ISEM XI). Lausanne, Switzerland, pp. 691–699

  10. Arthur A, Dickens P M and Cobb R C 1996 Using rapid prototyping to produce electrical discharge machining electrodes. Rapid Proto. J. 2(1): 4–12

    Article  Google Scholar 

  11. Durr H, Pilz R and Eleser N S 1999 Rapid tooling of EDM electrodes by means of selective laser sintering. Comput. Ind. 39: 35–45

    Article  Google Scholar 

  12. Bocking C, Rennie A E W, Bennett G R and Lewis N A B 2000 Electroforming of a thermojet master pattern for use as an electro-discharge machine electrode. In: Proceedings of the TCT Conference. Cardiff, Rapid News Publ, London, pp. 151–156

  13. Dimla D E, Hopkinson N and Rothe H 2004 Investigation of complex rapid EDM electrodes for rapid tooling applications. Int. J. Adv. Manuf. Technol. 23: 249–255

    Article  Google Scholar 

  14. Zhao J, Li Y, Zhang J, Yu C and Zhang Y 2003 Analysis of the wear characteristics of an EDM electrode made by selective laser sintering. J. Mater Process Technol. 138: 475–478

    Article  Google Scholar 

  15. Meena V K and Nagahanumaiah 2006 Optimization of EDM machining parameters using DMLS electrode. Rapid Proto. J. 12(4): 222–228

    Article  Google Scholar 

  16. Ferreira J C, Mateus A S and Alves N F 2007 Rapid tooling aided by reverse engineering to manufacture EDM electrodes. Int. J. Adv. Manuf. Technol. 34: 1133–1143

    Article  Google Scholar 

  17. Czyzewski J, Burzynski P, Gaweł K and Meisner, J 2009 Rapid prototyping of electrically conductive components using 3D printing technology. J. Mater. Process. Technol. 209: 5281–5285

  18. Amarim F L, Lohrengel A, Miller N, Schafer G and Czelusniak T 2013 Performance of sinking EDM electrodes made by selective laser sintering technique. Int. J. Adv. Manuf. Technol. 65: 1423–1428

    Article  Google Scholar 

  19. Pawar P, Anasane S, Ballav R and Kumar A 2016 Experimental study of electro-less copper coated on ABS material used for tooling in EDM machining process. J. Prod. Eng. 19(2): 27–32

    Google Scholar 

  20. Datta S, Bandyopadhyay A and Pal P K 2008 Grey based Taguchi method for optimization of bead geometry in submerged arc bead-on-plate welding. Int. J. Adv. Manuf. Technol. 39: 1136–1143

    Article  Google Scholar 

  21. Datta S, Bandyopadhyay A and Pal P K 2006 Desirability function approach for solving multi-objective optimization problem in submerged arc welding. Int. J. Manuf. Sci. Prod. 7(2): 127–135

    Google Scholar 

  22. Kumar P, Barua P B and Gaindhar J L 2000 Quality optimization (multi-characteristics) through Taguchi’s technique and utility concept. Qual. Reliab. Eng. Int. 16: 475–485

    Article  Google Scholar 

  23. Walia R S, Shan H S and Kumar P 2006 Multi-response optimization of CFAAFM process through Taguchi method and utility concept. Mater. Manuf. Process. 21: 907–914

    Article  Google Scholar 

  24. Mohanty S D, Datta, S, Mahapatra S S and Majumdar G 2009 Application of an integrated multi-objective optimization methodology in Flux Core Arc Welding (FCAW), Weld India. In: National Welding Seminar, Organized by Indian Institute of Welding, Kolkata

  25. Datta S, Nandi G, Bandyopadhyay A and Pal P K 2009 Application of PCA based hybrid Taguchi method for multi-criteria optimization of submerged arc weld: A case study. Int. J. Adv. Manuf. Technol. 45(3-4): 276–286

    Article  Google Scholar 

  26. Antony J and Antony F 2001 Teaching the Taguchi method to industrial engineers. Work Study 50(4): 141–149

    Article  Google Scholar 

  27. Liao H C 2006 Multi-response optimization using weighted principal component. Int. J. Adv. Manuf. Technol. 27: 720–725

    Article  Google Scholar 

  28. J Czyzewski J, Burzynski P, Gaweł K and Meisner J 2009 Rapid prototyping of electrically conductive components using 3D printing technology. J. Mater. Process. Technol. 209: 5281–5285

  29. Jha B, Ram K and Rao M 2011 An overview of technology and research in electrode design and manufacturing in sinking electrical discharge machining. J. Eng. Sci. Technol. Rev. 4(2): 118–130

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Centurion University of Technology and Management, Jatni Campus, Bhubaneswar, India

    S D Mohanty & R C Mohanty

  2. Department of Mechanical Engineering, National Institute of Technology Rourkela, Rourkela, 769008, India

    S S Mahapatra

Authors
  1. S D Mohanty
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. S S Mahapatra
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. R C Mohanty
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to S D Mohanty.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Mohanty, S.D., Mahapatra, S.S. & Mohanty, R.C. PCA based hybrid Taguchi philosophy for optimization of multiple responses in EDM. Sādhanā 44, 2 (2019). https://doi.org/10.1007/s12046-018-0982-z

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s12046-018-0982-z

Keywords

Search

Navigation