Optimization of process parameters of green electrical discharge machining using principal component analysis (PCA)

The objective of this research is to solve the multi-response parameter optimization problems of green manufacturing. A combination of gray relational analysis (GRA) associated with principal component analysis (PCA) method has been developed and has optimized the process parameters of green electrical discharge machining (EDM). The major performance characteristics selected are process time, relative tool wear ratio, process energy, concentration of aerosol, and dielectric consumption. The corresponding machining parameters are peak current, pulse duration, dielectric level, and flushing pressure. Initially, Taguchi (L9) orthogonal array has been used to perform the experimental runs and the optimal process parameters using the GRA approach. The weighting values corresponding to various performance characteristics are determined using PCA. Thereafter, analysis of variance (ANOVA) is applied to determine the relative significant parameter and percentage of contribution of machining parameters; the peak current is the most influencing parameter having 52.87 % of contribution followed by flushing pressure, dielectric level, and pulse duration with 22.00, 21.52, and 3.55 %, respectively. Finally, multiple regression analysis is performed to determine the relationship between machining parameters and performance characteristics. The Fuzzy-TOPSIS and VIKOR methodologies have been used to compare the results of the proposed methodology, and the optimum process parameters obtained are peak current (4.5 A), pulse duration (261 μs), dielectric level (80 mm), and flushing pressure (0.3 kg/cm2).