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Study of surface integrity and dimensional accuracy in EDM using Fuzzy TOPSIS and sensitivity analysis

(BQ) Surface integrity and dimensional accuracy remain critical concern in Electrical Discharge Machining (EDM). The current research work aims at investigating the influence of various EDM process parameters like pulse current (Ip), pulse-on time (Ton), tool work time (Tw) and tool lift time (Tup) on various aspects of surface integrity like white layer thickness (WLT), surface crack density (SCD) and surface roughness (SR). The dimensional accuracy, characterized by over cut (OC), has also been studied in the similar way. | Measurement 63 (2015) 364–376 Contents lists available at ScienceDirect Measurement journal homepage: www.elsevier.com/locate/measurement Study of surface integrity and dimensional accuracy in EDM using Fuzzy TOPSIS and sensitivity analysis S. Dewangan a, S. Gangopadhyay a,⇑, C.K. Biswas a,b a b AISI P20 tool steel Department of Mechanical Engineering, National Institute of Technology, Rourkela-769008, India Department of Petroleum Engineering, Universiti Teknologi Petronas, Ipoh, Malaysia a r t i c l e i n f o Article history: Received 28 November 2013 Received in revised form 26 September 2014 Accepted 27 November 2014 Available online 8 December 2014 Keywords: Electrical Discharge Machining (EDM) AISI P20 tool steel Fuzzy-TOPSIS Sensitivity analysis a b s t r a c t Surface integrity and dimensional accuracy remain critical concern in Electrical Discharge Machining (EDM). The current research work aims at investigating the influence of various EDM process parameters like pulse current (Ip), pulse-on time (Ton), tool work time (Tw) and tool lift time (Tup) on various aspects of surface integrity like white layer thickness (WLT), surface crack density (SCD) and surface roughness (SR). The dimensional accuracy, characterized by over cut (OC), has also been studied in the similar way. A response surface methodology (RSM) – based design of experiment has been considered for this purpose. The present study also recommends an optimal setting of EDM process parameters with an aim to improve surface integrity aspects after EDM of AISI P20 tool steel. This has been achieved by simultaneous optimization of multiple attributes (i.e. WLT, SCD, SR and OC) using Fuzzy-TOPSIS-based multi-criteria decision making (MCDM) approach. The optimal solution was obtained based on five decision makers’ preferences on the four responses (i.e. WLT, SCD, SR, and OC). From this analysis, an optimal condition of process parameters of Ip = 1 A, Ton = 10 ls, Tw = 0.2 s, and Tup = 1.5 s .