Multi-Objective Optimization of ECG Process Applying Soft Computing Techniques

Introduction

Rapid globalization has drastically changed the dynamics of the manufacturing industries across the globe which necessitates the use of alternative and concurrently superior materials for several applications commensurable with the deliberate use. In order to persevere in this competitive business environment industries are enduring several modifications by reorienting the traditional manufacturing process to non-traditional manufacturing process. In order to survive with the changes application of these evolving manufacturing techniques along with the contemporary materials is becoming popular gradually. Electrochemical Grinding (ECG) process is an amalgamation of electrochemical dissolution and mechanical abrasion which is one such very widely used non-conventional machining processes for machining complicated shapes in high strength electro-conductive materials, difficult-to-machine alloys, fragile, hardened and also heat sensitive parts (El-Hoffy, 2005). In ECG electrolyte is pumped in a small gap between the cathode grinding wheel and anode workpiece. Direct current pass through the electrolyte system. The major factor influencing ECG process are Electrolyte Concentration (C), Voltage (V), Depth of cut (D) Flow rate (F), physical properties of the workpiece, type of abrasive in the wheel, grain size of the abrasive particle, speed of the grinding wheel etc. (Reddy, Ramamoorthy, & Nair, 1998). As the material removal process is based on electrochemical dissolution of work material, the machined surfaces are free from residual stress and burr, thereby eliminating rejection caused by stress and cracks. In this machining process, there is no need for time-consuming secondary operations.