Journal of the Brazilian Society of Mechanical Sciences and Engineering (2018) 40:148

https://doi.org/10.1007/s40430-018-1069-9(0123456789().,-volV)(0123456789().,-volV)

TECHNICAL PAPER

Multi-response optimization of laser-assisted jet electrochemical

machining parameters based on gray relational analysis
Anup Malik1 • Alakesh Manna2

Received: 16 January 2017 / Accepted: 8 February 2018 / Published online: 20 February 2018
 The Brazilian Society of Mechanical Sciences and Engineering 2018

Abstract
The gray relational analysis is an important technique can be effectively used for forecasting, decision making in different
areas of manufacturing and products processing. In this research, the gray relational analysis has been employed to
optimize the input process parameters of the developed laser-assisted jet electrochemical machine (LA-JECM) for better
machining performance characteristics. Taguchi method-based design of experiment L16 (44) orthogonal array was
employed and experiments were carried out for investigation. The optimal parametric combination for multi-response
optimization was identified based on the collective implementation of Taguchi methodology and gray relational analysis
during microdrilling of Inconel-718. A LA-JECM has been developed and utilized for experimental investigation. The
experimental results revealed that there is 29.16% increase in MRR; 48.43% decrease in taper and 36.83% reduction in
surface roughness height, Ra (lm) when experiments were carried out on LA-JECM over JECM. The laser assistance with
JECM improves the machining quality and reduces machining time. Taguchi methodology and gray relational analysis
based multi-optimization found that the parametric setting, i.e., at supply voltage 80 V, electrolyte concentration 40 g/l,
inter-electrode gap 3 mm, and duty cycle 60% gives maximum material removal rate with minimum taper angle and
surface roughness height (Ra, lm) of the machined hole.

Keywords Laser-assisted jet electrochemical machining  Taguchi methodology  Gray relational analysis 
Multi-response optimization

Abbreviations Dof Degree of freedom

JECM Jet electrochemical machining
LA-JECM Laser-assisted jet electrochemical machining
VS Supply voltage (X1, volt)
EC Electrolyte concentration (X2, g/l) 1 Introduction
IEG Inter-electrode gap (X3, mm)
DC Duty cycle (X4, %) LA-JECM is a novel hybrid machining technique, which is
MRR Material removal rate (mg/min) a combination of a low power laser beam and jet elec-
TAP Taper (degree) trolytic chemical machining. In this process, material
Ra Surface roughness height (lm) removal takes place due to the dissolution of metal by
electrochemical action with assistance of laser heating.
This process can be effectively used for machining of
Technical Editor: Márcio Bacci da Silva. conductive materials. The main aim of utilizing the low
& Anup Malik
power laser beam is to increase the rate of dissolution of
[email protected] material from specific areas in the axial direction. It
decreases the rate of dissolution in the lateral direction, as a
Alakesh Manna
[email protected] result increases machining rate with dimensional accuracy
and surface quality. Laser beam does not remove any
1
School of Mechanical Engineering, Lovely Professional material from the workpiece surface; it only assists in
University, Phagwara, Punjab 144401, India
dissolution of metal by thermally activating the surface
2
Department of Mechanical Engineering, PEC University of layer. This technique can be utilized for machining of any
Technology, Chandigarh 160012, India

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difficult to machine conductive materials. In LA-JECM, can be fabricated in tens of seconds [14]. In electrochem-
tool (cathode) functioning as an electrolyte jet, hence ical micromachining, material removal rate is increased
complexity in designing of tools can be avoided. In this with increasing in pulse on time and supply current [15]. A
process, assistance of laser reduces stray electric field, tool with insulated side surface had been used to process
thereby reduces removal of material from the unwanted reverse-tapered holes from straight pre-drilled holes by
area. The removal of material can be concentrated from the controlling the applied voltage as well as feeding speed
specific machining zone by controlling the localization [16]. A gap of 2–4 mm is maintained between the two
effect with laser assistance. Therefore, due to the applica- electrodes, which is 10–20 times larger than conventional
tion of laser beam with jet electrochemical machine, there ECM process. In jet electrolytic drilling (JED) high
is distinguished reduction in taper and overcut. working voltage up to 500 V having DC along with elec-
Thermal energy supplied by laser beam increases the trolytes of high conductivity are used to obtain the high
rate of electrochemical reactions, thereby increases the current density required for achieving a high anodic dis-
material removal rate [1]. The utilization of laser in jet solution rate [17]. Higher current density results in a mir-
electrochemical machining process can minimize the ror-like surface, while lower current density realizes
spatter and recast layer which are usually generated in laser significantly rough and complicated structures which are
drilling [2, 3]. The better etching surface quality and the difficult to obtain with other machining processes [18]. For
higher etching efficiency can be obtained by laser assis- improving micromachining capabilities of ECM processes,
tance in electrochemical machining [4]. Temperature is a the application of ultra-short pulse current and ultra-small
main factor of this localization effect and should carefully gap size is recommended [19]. ECM process with pulsating
monitor to avoid spark damage because of electrolyte electrolyte is introduced, which is one of the unsteady
boiling [5]. The proposed ECM process was modeled to flows that are characterized by periodic fluctuations of the
investigate the electric potential and current distribution in mass flow rate and pressure. Authors claimed that a lower
the electrolyte and on the electrodes’ surface, and the surface roughness and higher material removal rate could
evolution of inner hole profile [6]. Surface finish, material be obtained using a pulsating electrolyte with proper pul-
removal rate and pit formations using solutions of sodium sating frequency and amplitude [20].
halides (bromide, chloride and fluoride, respectively) are The Gray Taguchi-based response surface methodology
compared with those obtained using the more commonly (GT-RSM) was used to optimize the plasma arc cutting
used sodium nitrate solution in electrolyte jet machining process parameters for cutting of stainless steel and claimed
(EJM) [7]. Authors discussed a novel electrochemical that this GT-RSM methodology improves quality charac-
machining process (ECM) method using tool electrodes teristics [21]. The utilization of orthogonal array and gray
with controlled conductive area ratio to shape the complex relational analysis is useful for multi-objective optimization
inner surface of holes [8]. for drilling of Al–SiC MMC as claimed by Singh et al. [22].
ECM provides an economical and effective method for Taguchi, adaptive neuro-fuzzy inference system (ANFIS),
machining high strength, heat-resistant materials into and gray relational analysis were used for studying, model-
complex shapes. Surface layer formed during ECM process ing and optimization of WEDM process parameters [23]. Lu
having no mechanical distortion, compressive stresses, et al. [24] coupled gray relational analysis (GRA) and prin-
cracks or thermal distortions [9]. An electrolytic jet cipal component analysis (PCA) to optimize the process
machining system was constructed and used to develop the parameters of high speed end milling. Taguchi-entropy
complicated three-dimensional surfaces [10]. Electro- weight-based gray relational analysis method was used to
chemical jet machining was used to successfully create optimize the USM parameters and neural network approach
textured dimple features in a hyper-eutectic Al–Si alloy for prediction of such parameters for machining of Ti-6Al-
[11]. The surface chemistry and near subsurface of elec- 4V [25]. The gray relational analysis and Taguchi method-
trolytic jet machined tracks has been explored. Authors ology were used for multi-response optimization of friction
claimed lower levels of surface carbon on electrochemi- stir welding parameters for joining of dissimilar Al alloys
cally machined surfaces that had undergone laser pre- [26]. Adalarasan and Sundaram [27] coupled gray relational
treatment to untreated machined surfaces [12]. The low analysis-based principal component analysis (GT-PCA) for
current density in the radial flow of the impinging jet parameter design in friction welding of Al/SiC/Al2O3 metal
deteriorates the surface roughness while the jet is passing matrix composite.
over the surface [13]. A patterned polydimethylsiloxane
(PDMS) mask with good flexibility is introduced as a mask 1.1 Gray relational analysis
in through-mask electrochemical micromachining
(TMEMM) for generating micro-dimple arrays on a Deng [28] explained that the gray relational analysis is a
cylindrical surface, in which thousands of micro-dimples method for measuring degree of approximation among the

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sequences based on gray relational grade. Figure 1 shows a The original sequence is normalized for ‘‘the-larger-the-
flow diagram explain the procedure adapted for optimiza- better’’ machining performance characteristics, e.g., mate-
tion using gray relational analysis. Gray relational analysis rial removal rate (MRR) based on the relation as follows:
is a method which can be applied to get the relationship Zio ðkÞ  min:Zoi ðkÞ
between groups of data. In this analysis, experimental Zip ðkÞ ¼ : ð1Þ
max:Zio ðkÞ  min:Zio ðkÞ
acquired data is normalized between values 0–1. In this
analysis, multi-parameter effects with multi-performance Taper angle and surface roughness is least desired
characteristics are converted into the single optimization phenomenon in machining process and their values should
with their gray relational grade and on their gray ranks be as low as possible. Therefore, if target value required for
[29]. ‘‘the-smaller-the-better’’ performance characteristics, e.g.,
taper and surface roughness height (Ra, lm), the original
1.2 Data pre-processing sequence is normalized as follows:
max:Zoi ðkÞ  Zoi ðkÞ
In gray relational analysis, data pre-processing is essential Zip ðkÞ ¼ : ð2Þ
max:Zio ðkÞ  min:Zio ðkÞ
as range and unit in one data sequence is different from
other data sequence. It is also true, when the range of data If there is ‘‘a specific target value’’ than original
sequence is more scattered, then target directions in sequence is normalized as follows:
 o 
sequences are different. It is a process of converting the Z ðkÞ  TV
p i
original data sequence to comparable data sequence. For Zi ðkÞ ¼ 1  :
max:fmax:Zio ðkÞ  TV; TV  min:Zio ðkÞg
data pre-processing, the acquired experimental results are
normalized in the range between 0 and 1 [30]. Method- ð3Þ
ologies used for data pre-processing in gray relational There is also simple method to normalize the original
analysis depend upon the characteristics of the original data sequence. In this case, original sequence is divided by first
sequence. value of the original sequence [i.e., Zo1(k)].

Fig. 1 Flow chart explain the

sequence of procedure adapted
for gray relational analysis

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Zio ðkÞ 2 Experimental planning

Zip ðkÞ ¼ ; ð4Þ
Z1o ðkÞ
2.1 Workpiece material
where Zoi (k) is the original sequence, Zip ðkÞ is the sequence
after data pre-processing, Zo1(k) is the first value of original Inconel-718 is a super alloy has numerous important
sequence, max:Zio ðkÞ is the largest value of original properties but machining of Inconel-718 in micron domain
sequence (Zoi (k)), min:Zio ðkÞ is the smallest value of origi- is really very difficult by any conventional machining
nal sequence (Zoi (k)), k = 1 for MRR, 2 for taper angle and methods. Table 1 represents the chemical composition of
3 for surface roughness, i = 1, 2, 3…, 16 for experiment Inconel-718 used as workpiece material.
numbers 1 to 16, and TV is the target value
2.2 Machine tool
1.3 Gray relational coefficients (GRCs) and gray
relational grade (GRG) Indigenously developed laser-assisted jet electrochemical
machine (LA-JECM) has been utilized for experimenta-
Doi(k) is the deviation sequence of reference sequence (Zr- tion. The developed LA-JECM has four main units such as
p
(k)) and comparability sequence ðZip ðkÞÞ. Therefore, (i) electrolyte supply unit consists of electrolyte collection
 
Doi ðkÞ ¼ Z p ðkÞ  Z p ðkÞ:
r i ð5Þ tank, strainer and pumping unit, (ii) laser assistance unit
consists of a laser source and laser generator, (iii) work-
After data pre-processing, gray relational coefficient is piece feed unit consists of three stepper motors for X-, Y-
calculated with the pre-processed sequence of the output and Z-axes movements, (iv) Power supply unit consists of
quality performance characteristics. The gray relational DC transformer (capacity ranges 0–500 V, 0–15 amp),
coefficient is calculated from the following relation: pulse controller to set pulse on and pulse off time
Dmin: þ fDmax: depending upon machining requirement. Table 2 repre-
ni ð k Þ ¼ 0\n  1; ð6Þ
Doi ðkÞ þ fDmax: sents the detail of the developed machine tool used for
  experiments.
 
Dmin: ¼ min:8j r i min:8k Zrp ðkÞ  Zjp ðkÞ; Figures 2 and 3 show the schematic and fabricated
  diagram of the developed LA-JECM used for machining of
 
Dmax: ¼ max:8j r i max:8k Zrp ðkÞ  Zjp ðkÞ; Inconel-718.

f ¼ distinguishing=identification coefficient: f r ½0; 1 2.3 Laser-assisted jet electrochemical machining

(LA-JECM) process approach
After calculating gray relational coefficients for each
performance characteristics then gray relational grade is
Laser-assisted jet electrochemical machining (LA-JECM)
calculated. Gray relational grade is the weighted sum of
is a hybrid machining process. In this machining, a low
gray relational coefficients and calculated using the fol-
power laser beam (500 mW) is combined with an elec-
lowing relation:
trolytic jet to make a non-contact tool electrode. The main
1 XN aim of combining the laser beam with an electrolytic jet is
ci ¼ w n ðkÞ;
k¼1 k i
N ð7Þ to enhance electrochemical dissolution from the surface of
XN
w k ¼ 1; the workpiece, which can give better precision and effi-
k¼1
ciency of machining. The laser beam is aligned coaxially
where ci is the gray relational grade for ith experiment, N is with the jet of the electrolyte. The laser beam pulses of
the no. of performance characteristics, and wk is the weight 10–15 Hz frequency expose the outer material surface,
factor for output performance characteristics. while a jet of electrolyte, under an appropriate electrical
Keeping in view, a laser-assisted electrochemical (LA- potential, impinges on the surface. The laser beam is
JECM) setup has been indigenously developed and utilized focused with the help of a lens before it strikes on the
for experimental investigation during microdrilling of workpiece to achieve higher laser power density (60 W/
Inconel-718. Inconel-718 is a superalloy, mainly used in mm2). The diameter of the electrolytic jet is comparatively
aerospace industry because of its high temperature larger as compared to the laser beam; therefore, it covers
strength, corrosion resistance and excellent fatigue prop- more surface area than the laser beam.
erties. Collectively, Taguchi design of experiments and The dissolution of material is occurred from wide part of
gray relational analysis were employed for multi-response the workpiece surface because of direct contact of elec-
optimization of the developed LA-JECM process parame- trolytic jet. But the area which is in contact of laser beam
ters for effective drilling of Inconel-718.

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Table 1 Chemical composition

Workpiece material Elements
of Inconel-718
Inconel-718 %Mo %Co %Al %C, 165 %Si, 251 %Ni, 216
10.77 0.22 0.16 0.034 0.105 Remaining
%Cr, 267 %Fe, 406 %V, 411 %Nb, 405 %W, 429
23.3 4.1 0.054 3.14 0.2
%Al, 308 %Zr, 339 %Ti, 337 %P, 185 %Mn, 403
0.185 0.099 0.699 0.004 0.031

Table 2 Specification of the developed machine tool used for experiments

Machine tool Indigenously developed laser-assisted jet electrochemical machine (LA-JECM)

Electrochemical part description Chemical used Sodium nitrate (NaNO3)

Electrolyte jet Demineralized water and sodium nitrate
Electrolyte jet concentration 20–80 g/l
Electrolytic jet velocity 10 m/s (constant)
Electrolytic jet diameter 800 lm
Electrolyte pumping unit Centrifugal pump (impeller material—Teflon)
Supply pressure (0–5 bar)
Workpiece material Inconel-718
Workpiece geometry Circular
Workpiece thickness 5 mm
Jet cell material Nylon
Nozzle material Ceramic
Nozzle diameter 800 lm
Machining chamber Glass
Strainer material Nylon yarn (cartridge type)
Laser source description Company Cobolt industries
Type Nd:YAG (DPSS-diode pumped solid state)
Name Samba, pulsed wave
Wavelength 532 nm
Average power 500 mW
Beam diameter * 400 lm
Power density 60 W/mm2
Workpiece feed system description Motion X, Y and Z direction
Motion controller Z-axis Servomotor controlled
X-axis and Y-axis Stepper motor controlled
Power supply description Voltage DC (0–500 V)
Current 0–15 amp
Pulse controller Pulse on and pulse off time (ls–min)

along with electrolytic jet, rate of dissolution process is electrode gap. Figure 5 describes the major material
intensified (Fig. 4). The major role of the application of removal mechanisms of LA-JECM. When laser beam
laser is to assist and direct the electrochemical energy, strikes on the workpiece surface it significantly influences
thereby increases rate of electrochemical dissolution. The its physical and chemical transformations. An additional
predominant mechanism of material removal is electro- source of heat is transferred from the incident laser beam
chemical dissolution supported by laser thermal energy energy into the workpiece. Therefore, the laser beam
transmitted to the workpiece. This electrolytic jet also energy thermally activates the surface of the workpiece in
helps in flushing out the reaction products from the inter- the impinged area, in turn increasing the current density in

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Fig. 2 Schematic of machine

tool (i.e., LA-JECM)

Fig. 3 Fabricated machine tool

setup (i.e., LA-JECM)

the localized zone, enhance metallic dissolution. The laser (i) The laser pulse strikes on the outer workpiece
beam influences the electrochemical machining through surface that transmit a quantum of heat energy to
localization effect during machining. the workpiece surface, due to which temperature
The localization effect and mechanisms of material in the specific area rises (say T1). The rise in
dissolution in the laser-assisted jet electrochemical temperature increases the current density (say J1).
machining process are explained with Figs. 6 and 7, According to Arrhenius’ law [31], higher current
respectively. In support of that the following points are density means a higher electrochemical dissolu-
listed below: tion in turn higher material removal rate.

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Fig. 4 Laser-assisted jet

electrochemical machining
process

Fig. 5 Roles of electrolytic jet

and laser beam in LA-JECM

Fig. 6 Localization effect in

LA-JECM

(ii) The energy provided by laser beam also increases (Ea1) for electrochemical reactions decreases,
the electrolyte temperature (say T1), enhance thereby initiated electrochemical reactions
conductivity (k1). The increase in conductivity rapidly.
yields high current, thereby increases current (iv) The reaction products created by diffusion in the
density. Rise in current density increases the machining area transfer easily with increasing in
velocity of the electrochemical reactions and the temperature in the machining zone.
again improves the material removal rate.
The assistance of laser beam with jet electrochemical
(iii) When temperature increases by the assistance of
machining process has great influence on the localization
laser beam, the requirement of activation energy

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Fig. 7 Localized machining

zone and machining mechanism
in LA-JECM

effect as mentioned above, which leads to higher machin- each control factor is selected based on pilot experiments.
ing rates during LA-JECM over JECM. Laser beam-aided The pilot experiments were carried out based on one factor
JECM also improves the quality and precision of machin- at a time (OFAT) approach to find the working range of the
ing, also more efficient machining may take place in the fabricated LA-JECM setup and discussed below.
specific areas due to the assistance of laser beam. It is due The effect of LA-JECM parameters, i.e., supply voltage,
to increase the current density in the machining zone, electrolyte concentration, inter-electrode gap and duty
hence machining is more focused in the case of LA-JECM cycle on different response characteristics such as material
as compared to JECM process. As a result, the laser removal rate, taper and surface roughness height, Ra (lm).
exposed the area of denser electric field, and significantly Figure 8a shows the effect of supply voltage on different
minimized the stray machining effect. Therefore, more response characteristics during machining of Inconel-718.
material removal takes place in axial (longitudinal) direc- However, during machining, it is observed that the material
tion rather than in the lateral direction, in turn reduces removal rate is negligible when machining operations were
taper. carried out with varying the supply voltage from 20 to
60 V keeping other parameters remain constant, i.e., 50 g/l
2.4 Design of experiment and process electrolyte concentration, 3 mm inter-electrode gap and
parameters 70% duty cycle. From this Fig. 8a, it is clear that the
supply voltage was insignificant when experiments were
In this study, supply voltage (VS, V), electrolyte concen- carried out with supply voltage up to 60 V. The MRR also
tration (EC, g/l), inter-electrode gap (IEG, mm) and duty marginally increases with increase in supply voltage from
cycle (DC, %) were chosen as four controllable 4-level 80 to 240 V. On the other hand, taper and surface rough-
factors and three response variables were material removal ness of the machined hole suddenly increased when
rate (MRR, mg/min), taper angle (TAP, degree) and sur- machining operations were carried out beyond 200 V
face roughness height (Ra, lm).Orthogonal array was supply voltage keeping other parameters remain constant is
selected based on the total degrees of freedom in system. shown in Fig. 8a. It may be due to high supply voltage,
The degrees of freedom are basically number of compar- thereby rise in temperature in the machining zone which in
isons made between design parameters. So in this research, turn increases hole taper and surface roughness height
total degrees of freedom were 13, as 12 owing to four suddenly. So the effective working range was identified for
parameters with four levels and one for overall mean. From machining of Inconel-718 on developed LA-JECM is 80 V
the calculated degree of freedom, it can be concluded that to 200 V supply voltage.
at least 13 experiments are to be conducted to estimate the Figure 8b shows the effect of electrolyte concentration
effects of all the four factors. Therefore, for the design of on the different response characteristics for Inconel-718.
LA-JECM experimental plan, the standard orthogonal However, during machining, it is observed that the material
array, which should have at least four columns with four removal rate is negligible when machining operations were
levels and at least 13 rows, should be selected for efficient carried out with varying the electrolyte concentration from
application of Taguchi methodology. Hence, a standard L16 5 to 15 g/l keeping other parameters remain constant, i.e.,
(44) orthogonal array has been selected for the present 140 V supply voltage, 3 mm inter-electrode gap and 70%
experimental investigation [32]. So in this study 16 duty cycle. From Fig. 8b, it is clear that the electrolyte
experiments with three replications have been carried out concentration was insignificant when experiments were
based on L16 (44) orthogonal array. The working range of carried out with electrolyte concentration up to 15 g/l. The

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Fig. 8 a Effect of supply voltage on different response characteristics. b Effect of electrolyte concentration on different response characteristics.
c Effect of inter-electrode gap on different response characteristics. d Effect of duty cycle on different response characteristics

MRR rapidly increases with increases in electrolyte con- keeping other parameters remain constant, i.e., 140 V
centration from 20 to 120 g/l. However, hole taper and supply voltage, 50 g/l electrolyte concentration and 70%
surface roughness of the machined hole suddenly increased duty cycle. So the working range of inter-electrode gap is
when machining operations were carried out beyond 80 g/l 2–5 mm for effective machining of Inconel-718 on devel-
electrolyte concentration keeping other parameters remain oped LA-JECM setup.
constant is shown in Fig. 8b. It is may be due to increase in Figure 8d shows the effect of duty cycle on the different
the concentration of ions in the machining zone, if elec- response characteristics for Inconel-718. However, during
trolyte concentration increases as a results generates high machining, it is observed that the material removal rate is
hole taper and surface roughness height. So the working negligible when machining operations were carried out
range of electrolyte concentration is 20 to 80 g/l for with varying the duty cycle from 30 to 50% keeping other
effective machining of Inconel-718 on developed LA- parameters remain constant, i.e., 140 V supply voltage,
JECM setup. 50 g/l electrolyte concentration and 70% duty cycle. From
Figure 8c shows the effect of inter-electrode gap on Fig. 8d, it is clear that the duty cycle was insignificant
response characteristics for Inconel-718. However, during when experiments were carried out with duty cycle up to
machining, it is observed that the material removal rate is 60%. The MRR also marginally increases with increase in
maximum at low inter-electrode gap and decreases with duty cycle from 60 to 100%. But hole taper and surface
increase in inter-electrode gap, but hole taper first decrea- roughness height Ra (lm) suddenly increased when
ses up to 3 mm inter-electrode gap and then increases. machined operation were carried out beyond 90% duty
However, surface roughness height is low at low inter- cycle. So the working range of the duty cycle is 60 to 90%
electrode gap and then increases with increase in inter- for effective machining of Inconel-718 on developed LA-
electrode gap when machining operations were carried out JECM.
with varying the inter-electrode gap from 1 to 7 mm

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Table 3 Input parameters and

Sr. No. Input parameters Parametric levels
their levels
1 Control factor Parameters Symbol Unit 1 2 3 4
2 A Supply voltage (X1) VS V 80 120 160 200
3 B Electrolyte conc. (X2) EC g/l 20 40 60 80
4 C Inter-electrode gap (X3) IEG mm 2 3 4 5
5 D Duty cycle (X4) DC % 60 70 80 90

Table 3 represents the different parameters and their levels Fig. 9, it is clear that the material removal rate increases
considered for experiments after one factor at a time OFAT, i.e., with increase in electrolyte concentration. Electrolyte
feasibility experiments and analysis of the acquired results. concentration has an important effect on the material
removal rate in both machining cases, i.e., LA-JECM and
2.5 Measuring equipment’s JECM. When electrolyte concentration increases, it
increases the number of charge carries, thereby increases
An Electronic Balance of resolution 0.1 mg is used for material removal rate. It is clearly visible from Fig. 9 that
weighing the workpiece before and after each machining the laser assistance enhances the material removal rate
operation. Workpiece was completely cleaned and dried because it enhances the rate of electrochemical reactions.
before weighing of workpiece sample. The material removal Figure 10 shows the variation of taper with duty cycle.
was calculated from the difference of weight of workpiece From Fig. 10, it is clear that the taper increases with
sample before and after machining. The material removal increase in duty cycle. When duty cycle (%) increases then
rate (MRR, mg/min) was determined as per relationship as current density in the machining zone increases and time
explained in Eq. (8). Taper (TAP, degree) per unit length for dissolution process also increases enhance rate of dis-
was measured utilized the microscope of DT-110 Hybrid solution. From Fig. 10, it is clearly seen that the effect of
lEDM of resolution 0.1 lm. Diameter of the machined hole laser assistance is very significant at the small duty cycles
was directly read out from the screen of the machine. Taper as compared to high duty cycles. Hence, machining at low
angle was calculated from the acquired reading as per the duty cycles with LA-JECM is recommended.
relationship as explained in Eq. (9). Surface roughness Design of experiments based orthogonal array L16 (44)
height (Ra, lm) was measured with the help of SURFCOM was used for conducting experiments. Table 4 shows
130A (Tokyo Seimitsu Co., Japan) surface roughness mea- orthogonal array with actual parametric setting, mean value
suring equipment. Machining time is recorded with the help of results for LA-JECM and JECM with percentage
of digital stop watch of accuracy 0.1 s. improvement in the response characteristics when
Wb  Wa machining was done with LA-JECM over JECM process.
MRR ¼ ; ðmg=minÞ; ð8Þ The effect of laser assistance during machining of Inconel-
MT
  718 on developed LA-JECM can be theoretically deter-
1 Dtop  Dbottom mined in terms of % of change in MRR, TAP and SR as per
TAP ¼ tan ; ðdegreesÞ; ð9Þ
ð2  Tw Þ the described Eqs. (10–12), respectively, as follows:
where Wb is the weight of workpiece before machining, Wa
is the weight of workpiece after machining, MT is the 5.5
machining time, Dtop is the diameter on the top of Supply voltage : 140 volt
Material Removal Rate (mg/min)

5 Inter-electrode gap : 3 mm
machined hole (in lm), Dbottom is the diameter on the Duty cycle : 70 %
bottom of machined hole (in lm), Tw is the thickness of 4.5
workpiece (in mm), MRR is the material removal rate (mg/ 4
min), and TAP is the taper angle (degrees).
3.5

3
JECM
3 Results and discussion 2.5 LAJECM
2
3.1 Comparative analysis between LA-JECM
and JECM processes 1.5
20 50 80 110 140
Electrolyte Concentration (g/l)
Figure 9 shows the variation of material removal rate
(MRR, mg/min) with electrolyte concentration. From Fig. 9 Effect of electrolyte concentration on material removal rate

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Supply voltage : 160 volt SRJECM  SRLAJECM
11 Electrolyte Concentration : 50 g/l % decrease in SR ¼  100;
10 Inter-electrode gap : 3 mm SRJECM
9 ð12Þ
Taper (degrees)

8
7 where MRRLA-JECM is the material removal rate with laser
6 assistance in JECM, MRRJECM is the material removal rate
5 JECM without laser assistance in JECM, TAPLA-JECM is the taper
4 LAJECM with laser assistance in JECM, TAPJECM is the taper
3
without laser assistance in JECM, SRLA-JECM is the surface
2
roughness with laser assistance in JECM, and SRJECM is
1
50 60 70 80 90 the surface roughness without laser assistance in JECM
Duty cycle (%) The percentage of improvement in material removal
rate, reduction in taper and reduction in surface roughness
Fig. 10 Effect of duty cycle on taper height based on orthogonal array (L16) used was 29.16,
  48.43 and 36.83%, respectively, as shown in Table 4. It is
MRRLAJECM  MRRJECM due to the concentration of energy supplied and heating in
% increase in MRR ¼
MRRJECM the specific area by assistance of laser. The dissolution of
 100; metal also takes place from the specific zone without spark
ð10Þ affected. Energy transfer by laser beam is constant per unit
  time; thereby energy transfer by laser beam is less if
TAPJECM  TAPLAJECM
% decrease in TAP ¼ machining operation is carried out for shorter period of
TAPJECM time. Again, less laser energy transfer during machining
 100;
means worse process localization, it occurs when shorter
ð11Þ machining time implies. At low supply voltage and mod-
erate inter-electrode gap between electrodes, the

Table 4 Experimental results

Exp. No. Level Mean value of Mean value of Improvement in LA-JECM over JECM
acquired results acquired results
LA-JECM JECM % Increase in MRR % Decrease in TAP % Decrease in Ra
X1 X2 X3 X4 MRR TAP Ra MRR TAP Ra

1 80 20 2 0.6 1.72 3.21 4.51 1.42 3.83 7.14 21.12 16.18 36.83
2 80 40 3 0.7 1.56 4.24 4.90 1.41 5.52 5.52 10.63 23.18 11.23
3 80 60 4 0.8 1.84 4.89 6.75 1.71 5.56 8.58 7.60 12.05 21.32
4 80 80 5 0.9 2.12 7.35 9.56 1.82 12.47 11.67 16.48 41.05 18.08
5 120 20 3 0.8 2.72 3.45 7.65 2.52 6.69 8.82 7.93 48.43 13.26
6 120 40 2 0.9 5.16 6.83 8.93 4.85 7.90 10.21 6.39 13.54 12.53
7 120 60 5 0.6 1.24 6.23 6.89 0.96 7.26 8.27 29.16 14.18 16.68
8 120 80 4 0.7 2.68 5.53 5.56 2.51 6.24 7.20 6.77 11.37 22.77
9 160 20 4 0.9 3.40 5.97 7.65 3.09 7.11 9.91 10.03 16.03 22.80
10 160 40 5 0.8 2.16 7.25 8.90 1.90 8.66 9.62 13.68 16.28 7.48
11 160 60 2 0.7 5.24 5.52 7.20 4.93 6.87 9.02 6.28 19.65 20.17
12 160 80 3 0.6 4.10 4.84 7.69 3.81 5.46 8.67 7.61 11.35 11.30
13 200 20 5 0.7 1.80 6.25 5.56 1.47 7.30 6.22 22.44 14.38 10.61
14 200 40 4 0.6 2.89 4.98 4.36 2.67 5.57 5.01 8.23 10.59 12.97
15 200 60 3 0.9 6.21 6.98 9.87 6.10 7.85 11.71 1.80 11.08 15.71
16 200 80 2 0.8 6.75 7.98 9.43 6.59 10.66 11.05 2.42 25.14 14.66
X1, supply voltage (V); X2, electrolyte concentration (g/l); X3, inter-electrode gap (mm); X4, Duty cycle (%); MRR, material removal rate (in mg/
min); TAP, taper angle (in degree); Ra, surface roughness height (in lm)

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Fig. 11 SEM photographs of machined holes generated by a JECM and b LA-JECM

Fig. 12 SEM photographs of machined holes generated by a JECM and b LA-JECM

temperature of electrolyte in the machining zone increases electrolyte concentration. There is also the presence of
by assistance of laser, thereby increases dissolution of scale deposition on the surroundings of the hole. Whereas
metal. Here the dissolution of metals occurs by the com- from Fig. 11b, it is clear that the periphery of the machined
bined action of electrochemical and laser. The concentra- hole is circular with better surface quality as compared to
tion of electrochemical energy in the specific area cause of the machined hole Fig. 11a generated by JECM.
dissolution of metal by the action of laser also decreases Figure 12a, b shows the SEM photographs of the
the taper during machining. However, H2 gas is formed at machined holes generated by JECM and laser-assisted
the machining zone when machining operations were car- JECM, respectively, at 160 V supply voltage, 40 g/l elec-
ried out at high supply voltage and low inter-electrode gap trolyte concentration, 80% duty cycle and 4 mm inter-
which deviated the alignment of laser beam and deteriorate electrode gap. Figure 12a clearly demonstrates the pres-
the machining performance. ence of damage boundary on the periphery of the machined
Figure 11a, b show the SEM photographs of the hole which deteriorates the quality of machining. There are
machined holes generated by JECM and LA-JECM, clear evidence of the melting and deposition of the material
respectively, at 200 V supply voltage, 80 g/l electrolyte on the machined hole periphery because of high supply
concentration, 90% duty cycle and 2 mm inter-electrode voltage and duty cycle. Whereas from Fig. 12b, it is clear
gap. Figure 11a shows the major damage around the that there is no evidence of damage on the periphery of the
machined hole edge due to supply of high voltage and machined hole. It is may be due to the dissolution of

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Fig. 13 SEM photographs of cross-sectional view of holes generated by a JECM and b LA-JECM

material by electrochemical action with guidance of the The deviation sequence can be calculated using Eq. (5)
laser beam. It usually helps in focusing the electrochemical as follows:
action in the longitudinal direction, thereby distorts and  
Doi ð1Þ ¼ Z p ð1Þ  Z p ð1Þ ¼ j1:00  0:0871j ¼ 0:9129;
r i
damages in the periphery of the machined hole are very
less as compared to the generated hole machined with  
Doi ð2Þ ¼ Zrp ð2Þ  Zip ð2Þ ¼ j1:00  1:00j ¼ 0;
JECM.  
Figure 13a, b shows the cross-sectional view of the Doi ð3Þ ¼ Zrp ð3Þ  Zip ð3Þ ¼ j1:00  0:9728j ¼ 0:0272:
machined hole generated by JECM and laser-assisted
Therefore, Do1 ðkÞ ¼ ½0:9129; 0; 0:0272:
JECM, respectively, at 160 V supply voltage, 80 g/l elec-
Table 6 also represents the results of comparability
trolyte concentration, 60% duty cycle and 3 mm inter-
sequence and deviation sequence for 16 experiments (i.e.,
electrode gap. From Fig. 13a, b it can be easily seen that
for i = 1–16).
the entry and exit of the hole shown in Fig. 13a is very
From Table 6, Dmax: ðkÞ and Dmin: ðkÞ are calculated as
large as compared to the hole shown in Fig. 13b. There is
follows:
also higher taper along the hole shown in Fig. 13a as
compared to the hole shown in Fig. 13b. Therefore, laser- Dmax: ¼ Do7 ð1Þ ¼ Do16 ð2Þ ¼ Do15 ð3Þ ¼ 1:00;
assisted jet electrochemical machining (LA-JECM) is rec- Dmin: ¼ Do16 ð1Þ ¼ Do1 ð2Þ ¼ Do14 ð3Þ ¼ 0:00:
ommended over the JECM for the machining of Inconel-
718. If all the parameters are given equal preference then
value of distinguishing coefficient (f) should be taken as
3.2 Optimal experimental run for LA-JECM 0.5. Afterwards, gray relational coefficient (GRC) for each
process experiment of L16 orthogonal array was calculated using
Eq. (6) and listed in Table 7.
The acquired results shown in Table 5 are utilized for Table 7 represents the gray relational grade for each
optimization of the developed LA-JECM machine param- experimental run along with their grade rank. The higher
eters for better machining response characteristics, e.g., value of gray relational grade represents the corresponding
MRR, taper and surface roughness height (Ra, lm). experimental result which is very close to ideal normalized
Data preprocessing was done by utilizing the relation value. In Table 7, it is seen that experiment 1 has the
Eq. (1) for material removal rate, and the relation Eq. (2) highest gray relational grade that means it has best multiple
for taper and surface roughness height (Ra, lm). It is a performance characteristics among sixteen experiments.
process of reassigning the data in original order into a Figure 14 shows the gray relational grade according to the
comparative order. The sequences obtained after data pre- experimental run.
processing are represented in Table 6.

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Table 5 Experimental results

Exp. No. Level Mean value of acquired results
LA-JECM
X1 X2 X3 X4 MRR (mg/min) TAP (degrees) Ra (lm)

1 80 20 2 0.6 1.72 3.21 4.51

2 80 40 3 0.7 1.56 4.24 4.90
3 80 60 4 0.8 1.84 4.89 6.75
4 80 80 5 0.9 2.12 7.35 9.56
5 120 20 3 0.8 2.72 3.45 7.65
6 120 40 2 0.9 5.16 6.83 8.93
7 120 60 5 0.6 1.24 6.23 6.89
8 120 80 4 0.7 2.68 5.53 5.56
9 160 20 4 0.9 3.40 5.97 7.65
10 160 40 5 0.8 2.16 7.25 8.90
11 160 60 2 0.7 5.24 5.52 7.20
12 160 80 3 0.6 4.10 4.84 7.69
13 200 20 5 0.7 1.80 6.25 5.56
14 200 40 4 0.6 2.89 4.98 4.36
15 200 60 3 0.9 6.21 6.98 9.87
16 200 80 2 0.8 6.75 7.98 9.43

Table 6 Sequences after pre-processing of data

Performance characteristics MRR TAN Ra Deviation sequences
Reference sequence (Zpr (1)) = 1.0000 (Zpr (2)) = 1.0000 (Zpr (3)) = 1.0000
Experiment no. Comparability sequence (Zpi (k)) Doi (MRR) Doi (TAN) Doi (Ra)

1 0.0871 1.0000 0.9728 0.9129 0.0000 0.0272

2 0.0581 0.7841 0.9020 0.9419 0.2159 0.0980
3 0.1089 0.6478 0.5662 0.8911 0.3522 0.4338
4 0.1597 0.1321 0.0563 0.8403 0.8679 0.9437
5 0.2686 0.9497 0.4029 0.7314 0.0503 0.5971
6 0.7114 0.2411 0.1706 0.2886 0.7589 0.8294
7 0.0000 0.3669 0.5408 1.0000 0.6331 0.4592
8 0.2613 0.5136 0.7822 0.7387 0.4864 0.2178
9 0.3920 0.4214 0.4029 0.6080 0.5786 0.5971
10 0.1670 0.1530 0.1760 0.8330 0.8470 0.8240
11 0.7260 0.5157 0.4846 0.2740 0.4843 0.5154
12 0.5191 0.6583 0.3956 0.4809 0.3417 0.6044
13 0.1016 0.3627 0.7822 0.8984 0.6373 0.2178
14 0.2995 0.6289 1.0000 0.7005 0.3711 0.0000
15 0.9020 0.2096 0.0000 0.0980 0.7904 1.0000
16 1.0000 0.0000 0.0798 0.0000 1.0000 0.9202

Figure 15 shows the effect of each machining parameter ðVS Þ1 ¼ ð0:7674 þ 0:6271 þ 0:4938 þ 0:3616Þ=4
on the gray relational grade at their different levels. For ¼ 0:5625;
supply voltage (parameter, Vs), placed in the first column
(Table 5) as per orthogonal array L16 (44), experimental ðVS Þ2 ¼ ð0:5901 þ 0:4691 þ 0:4319 þ 0:5357Þ=4
runs from 1 to 4 are at first level, the gray relational grade ¼ 0:5067;
is calculated for these levels 1–4 as follows:

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Table 7 Calculated gray relational coefficient with gray relational grade

Exp. No. Orthogonal array L16 (44) Gray relational coefficient (GRC’s) Gray relational grade (GRG) Rank
X1 X2 X3 X4 MRR TAP Ra
ni(1) ni(2) ni(3)

1 1 1 1 1 0.3539 1.0000 0.9484 0.7674 1

2 1 2 2 2 0.3468 0.6984 0.8361 0.6271 3
3 1 3 3 3 0.3594 0.5867 0.5354 0.4938 11
4 1 4 4 4 0.3730 0.3655 0.3463 0.3616 16
5 2 1 2 3 0.4060 0.9086 0.4557 0.5901 4
6 2 2 1 4 0.6340 0.3972 0.3761 0.4691 12
7 2 3 4 1 0.3333 0.4413 0.5212 0.4319 14
8 2 4 3 2 0.4036 0.5069 0.6966 0.5357 7
9 3 1 3 4 0.4513 0.4636 0.4557 0.4569 13
10 3 2 4 3 0.3751 0.3712 0.3776 0.3746 15
11 3 3 1 2 0.6460 0.5080 0.4924 0.5488 6
12 3 4 2 1 0.5097 0.5940 0.4527 0.5188 9
13 4 1 4 2 0.3575 0.4396 0.6966 0.4979 10
14 4 2 3 1 0.4165 0.5740 1.0000 0.6635 2
15 4 3 2 4 0.8361 0.3874 0.3333 0.5189 8
16 4 4 1 3 1.0000 0.3333 0.3521 0.5618 5
Total mean value of gray relational grade 0.5261

Fig. 14 Gray relational grade 0.8

with experiment number Grey relaonal grade Mean Grey relaonal grade
0.75
0.7
Grey relational Grade

0.65
0.6
0.55
0.5
0.45
0.4
0.35
0.3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Experiment Number

ðVS Þ3 ¼ ð0:4569 þ 0:3746 þ 0:5488 þ 0:5188Þ=4 Larger gray relational grade indicates closer product
¼ 0:4748; quality to the ideal value. Therefore, larger gray relational
grade is desired to get the optimum performance. There-
ðVS Þ4 ¼ ð0:4979 þ 0:6635 þ 0:5189 þ 0:5618Þ=4 fore, the optimal parametric setting for higher MRR and
¼ 0:5605: lower taper angle and surface roughness height (Ra) is
Similarly, the mean of gray relational grade for each A1B2C2D1 (Table 8). Furthermore, ANOVA has also per-
level of the other machining parameters (i.e., electrolyte formed on gray relational grade to identify the contribution
concentration, inter-electrode gap and duty cycle) can be of each process parameter which affects the three response
calculated. Table 8 represents the mean of the gray rela- characteristics (i.e., MRR, taper angle and surface rough-
tional grade with respect to each parameter and their ness height).
respective levels. Figure 15 shows the gray relational grade The difference between maximum and minimum aver-
with respect to the different machining parameter levels. age gray relational grade for supply voltage is 0.0877, for
electrolyte concentration is 0.0836, for inter-electrode gap

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Fig. 15 Machining parameters Grey relaonal grade Mean grey relaonal grade
0.6
levels with gray relational grade

Grey Relational Grade

0.55

0.5

0.45

0.4
A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4
Machining Parameters Level

Table 8 Gray relational grades

Input parameters Symbol Gray relational grade Difference (Max.–Min.)
for each factor
Level
1 2 3 4
a
Supply voltage VS 0.5625 0.5067 0.4748 0.5605 0.0877
Electrolyte concentration EC 0.5336 0.5781a 0.4984 0.4945 0.0836
a
Inter-electrode gap IEG 0.5637 0.5867 0.5375 0.4165 0.1702
Duty cycle DC 0.5954a 0.5524 0.5051 0.4516 0.1438
a
Levels for optimum gray relational grade

is 0.1702 and for duty cycle is 0.1438. These differences predominant parameters that affect the gray relational
give an idea about the most influential input process grade, and hence contributes most in increasing MRR, and
parameter that controls output quality characteristics. The decreasing taper and surface roughness height.
input parameter with larger difference mostly controls the Figure 16a shows the SEM photographs of the machined
output quality characteristics. The controllable factor is hole generated at 80 V supply voltage, 40 g/l electrolyte
inter-electrode gap with difference of gray relational grade concentration, 3 mm inter-electrode gap and 60% duty
0.1702, followed by the duty cycle 0.1438, supply voltage cycle on developed LA-JECM. From Fig. 16a, it is clear
0.0877 and electrolyte concentration 0.0836. that the machined hole is circular in nature and hole taper is
It was observed that lower supply voltage (80 V) pro- very less or negligible. There is no evidence of any edge
duces lower surface roughness height (Ra) and taper angle damage effect present around the periphery of the
as compared to the higher supply voltage (200 V). At machined hole. The surrounding hole surface is very fine
higher supply voltage, taper angle is increased because of and acceptable according to the machining requirement of
the surface damage around the hole. This also leads lower taper and surface roughness. Figure 16b shows the
towards increase in surface roughness. Therefore, it is clear cross-sectional view of the same machined hole (Fig. 16a).
that the machining performance is better at low value of the There is slight presence of taper along the depth of hole.
supply voltage. Figure 15 shows the machining parameter Figure 17 shows the optical photographs of the
levels with gray relational grade. It is clear that there is machined holes generated by LA-JECM, respectively, at
decrease in gray relational grade with increase in duty parametric conditions of 160 V supply voltage, 80 g/l
cycle and beyond 40 g/l electrolyte concentration (param- electrolyte concentration, 60% duty cycle and 3 mm inter-
eter: B2), as well as beyond 3 mm inter-electrode gap electrode gap. Figure 17 shows the optical photograph of
(parameter: C2). This shows that lower value of all these the machined hole taken by the microscope of DT-110
factors generates optimal machining performance Hybrid lEDM of resolution 0.1 lm. Diameter of the
characteristics. machined hole was directly read out from the screen of the
Table 9 represents the ANOVA for gray relational machine. From Fig. 17, it is clear that the diameter of hole
grade. Percentage contributions for each term affecting on the top of machined hole is 952 lm and on the bottom
gray relational grade are Table 9. Table 9 clearly indicates of the hole is 912 lm. This hole was generated on Inconel
that the inter-electrode gap and duty cycle are the two 718 utilized LA-JECM process. It is found that the hole

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Table 9 ANOVA of gray

Symbol Machining parameter Dof SS MS % Contribution
relational grade
A Supply voltage 3 0.0221 0.0074 13.62
B Electrolyte concentration 3 0.0181 0.0060 11.16
C Inter-electrode gap 3 0.0689 0.0230 42.48
D Duty cycle 3 0.0459 0.0153 28.30
Error 3 0.0071 0.0024 4.44
Total 15 0.1622
Dof, degree of freedom; SS, sum of squares; MS, mean squares

Fig. 16 SEM photograph of machined hole machined by LA-JECM. a Top view. b Cross-sectional view

produced with LA-JECM process is very good in shape; it concentration, 3 mm inter-electrode gap and 60% duty
is very circular in nature. So from the above analysis, it can cycle on developed LA-JECM. From Fig. 18, it is clear that
be concluded that the LA-JECM process is better for hole there is slight presence of taper along the depth of hole.
generation than JECM process. There is no evidence of any edge damage effect present
Figure 18 shows the optical photograph of the machined around the cross-section of the machined hole. Generated
hole generated at 80 V supply voltage, 20 g/l electrolyte hole shape is fine and acceptable according to the
machining requirement of holes produced in the micro
domain. The diameter on the top of the hole is 952 lm and
on the bottom is 756 lm on the hole depth of 700 lm. The
produced hole is less than 1000 lm, so this LA-JECM
process is effectively used for the production of holes in the
micro domain.

3.3 Most influential factor

Influence of input parameters on output performance

characteristics can also be find out using gray relational
analysis. Input process parameter levels are comparability
sequence for four controllable process parameters, as rep-
resented in Table 5. Data pre-processing was performed as
per Eq. (4). Data sequence is normalized by initial value
and the results are tabulated in Table 10. Similarly, devi-
Fig. 17 Top view of the machined holes generated by LA-JECM ation sequences were calculated using same methodology

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estimated and constructed the gray relational grades matrix

Eq. 13.
Utilized the gray relational coefficient and grade for
MRR (Table 11), taper and surface roughness height (Ra),
the gray relational grades can be arranged in the following
way as
2 3
cðMRR; Vs Þ cðMRR; Ec Þ cðMRR,IEGÞ cðMRR; Dc Þ
6 7
c ¼ 4 cðTAP; Vs Þ cðTAP; Ec Þ cðTAP; IEGÞ cðTAP; Dc Þ 5
cðRa ; Vs Þ cðRa ; Ec Þ cðRa ; IEGÞ cðRa ; Dc Þ
2 3
0:6463 0:6513 0:6298 0:7023
6 7
c ¼ 4 0:6490 0:6170 0:6671 0:5496 5:
0:6975 0:6232 0:5527 0:5897
ð13Þ
By comparing rows 1–3 from obtained matrix, it can be
explained as follows:
In the first row, cðMRR; Dc Þ [ cðMRR; Ec Þ [
Fig. 18 Sectional view of the machined holes generated by LA-
JECM
cðMRR; Vs Þ [ cðMRR; IEGÞ, representing the order of
preference for controllable factors, such as DC, EC, VS, and
as discussed above. Gray relational coefficients (GRCs) IEG that govern material removal rate (MRR). It is also
were obtained by substituting deviation sequences and found that the gray relational grade for material removal
distinguishing coefficient using Eq. (5). The average of rate was maximum (0.7023) as compared to other input
gray relational coefficient was taken by assigning equal process parameters under investigation. It means the duty
weight and identified gray relational grade. Table 11 rep- cycle is the most important parameter for defining material
resents the gray relational coefficient and grade for MRR. removal rate. From the second row, behavior of input
Similar way gray relational coefficient and grade for taper process parameters on taper angle is found out. This row
angle (TAP) and surface roughness height (Ra) were gives the order of gray relational grade for taper angle
(TAP) and it is found to be

Table 10 Sequence after data pre-processing

Experiment No. Comparability sequence Reference sequence
Supply voltage Electrolyte concentration Inter-electrode gap Duty cycle MRR TAP Ra

1 1.0 1 1.0 1.000 1 1 1

2 1.0 2 1.5 1.167 0.907 1.321 1.086
3 1.0 3 2.0 1.333 1.070 1.523 1.497
4 1.0 4 2.5 1.500 1.232 2.289 2.120
5 1.5 1 1.5 1.333 1.581 1.075 1.696
6 1.5 2 1.0 1.500 3.000 2.128 1.980
7 1.5 3 2.5 1.000 0.721 1.941 1.528
8 1.5 4 2.0 1.167 1.558 1.723 1.233
9 2.0 1 2.0 1.500 1.977 1.860 1.696
10 2.0 2 2.5 1.333 1.256 2.259 1.973
11 2.0 3 1.0 1.167 3.047 1.720 1.596
12 2.0 4 1.5 1.000 2.384 1.508 1.705
13 2.5 1 2.5 1.167 1.047 1.947 1.233
14 2.5 2 2.0 1.000 1.680 1.551 0.968
15 2.5 3 1.5 1.500 3.610 2.174 2.188
16 2.5 4 1.0 1.333 3.924 2.486 2.091

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Table 11 Gray relational coefficient and gray relational grade for MRR
Supply voltage Electrolyte concentration Inter-electrode gap Duty cycle

Gray relational coefficient 1 1 1 1

0.88968 0.55874 0.711436 0.832851
0.914634 0.417622 0.611204 0.831248
0.763747 0.333333 0.535531 0.828590
0.902527 0.704326 0.947505 0.839326
0.333333 0.580537 0.422299 0.463423
0.490517 0.377832 0.451095 0.822801
0.928218 0.361735 0.767857 0.768159
0.970246 0.586192 0.984512 0.730889
0.502008 0.650376 0.540281 0.943898
0.417362 0.967156 0.416643 0.407967
0.661376 0.461333 0.623188 0.483486
0.340445 0.967156 0.501544 0.915224
0.477707 0.812207 0.820426 0.655783
0.403226 0.694082 0.409295 0.380414
0.344986 0.947945 0.333333 0.333333
Gray relational grade (MRR) 0.646251 0.651286 0.629759 0.702337
Similar way gray relational coefficient and grade for taper angle (TAP) and surface roughness height (Ra) were calculated and found as
Gray relational grade (Taper) 0.648954 0.617048 0.667130 0.549614
Gray relational grade (Surface roughness height, Ra) 0.697506 0.623241 0.552708 0.589682

cðTAP; IEGÞ [ cðTAP; Vs Þ [ cðTAP; Ec Þ [ cðTAP; Dc Þ, 4 Conclusions

which shows that the taper angle is the most influential
factor for inter-electrode gap (0.6671) followed by supply A laser-assisted jet electrochemical machine (LA-JECM)
voltage (0.6490), electrolyte concentration (0.6170) and has been indigenously developed and utilized for drilling of
duty cycle (0.5496). The most influential factor for surface Inconel-718. Taguchi method based design of experiments
roughness height (Ra, lm) is calculated with the help of L16 (44) orthogonal array has been employed and a series of
third row of the matrix. The gray relational grade for sur- experiments have been carried out for experimental
face roughness height(Ra, lm) is found to be in the order of investigation on developed LA-JECM. The gray relational
cðRa ; Vs Þ [ cðRa ; Ec Þ [ cðRa; DcÞ [ cðRa ; IEGÞ, which analysis has been employed and multi-response optimiza-
shows that the supply voltage (0.6975) is the most influ- tion was done to study the machining characteristics and
ential factor for calculating the surface roughness height microdrilling behavior during drilling of Inconel-718.
(Ra, lm) followed by the electrolyte concentration Material removal rate, taper and surface roughness height
(0.6232), duty cycle (0.5897) and inter-electrode gap (Ra, lm) were considered as output characteristics for
(0.5527). microdrilling of Inconel-718. Based on the acquired results
The effect of input process parameters on the output and analysis, the following conclusions are listed as
quality characteristics can be easily determined form the follows:
columns of the above matrix. By algebraic sum of gray
(i) Experimental results revealed that there is 29.16%
relational grades along the columns also highlighted the
increase in material removal rate; 48.43%
influence of input process parameters on response charac-
decrease in taper angle and 36.83% reduction in
teristics. Here maximum summation value among columns
surface roughness height, Ra (lm) when experi-
1–4 (i.e., C1, C2, C3 and C4), it is identified that the highest
ments were carried out utilized developed LA-
values corresponding to column C1 (i.e., 0.6463, 0.6490,
JECM over JECM. The laser assistance with
and 0.6975). That means supply voltage is the strongest
JECM improves the machining quality and pre-
comparability sequence among other input process
cession over JECM.
parameters. It also means that supply voltage has strongest
(ii) The optimal parametric combination for multi-
correlation with material removal rate, taper and surface
response characteristics is A1B2C2D1, i.e., at 80 V
roughness height (Ra, lm).
supply, 40 g/l concentration, 3 mm IEG and 60%

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