MULTIPLE PROCESS PARAMETER

OPTIMIZATION OF WIRE ELECTRIC

DISCHARGE MACHINING USING
PCA-TOPSIS, TOPSIS TECHNIQUES

By

TUMATI SRINIVASA RAO

(Y16MTMD810)

Under the Guidance of

Dr. G. SRINIVASA RAO .Ph.D

Professor, Department Of Mechanical Engineering

 ABSTRACT
• The aim of this project is to find the optimum
process parameters of WEDM for machining
the titanium and to analyse the influence of
the machining parameters Ton , Toff, Ip, Sv
(pulse on time, pulse off time, input current,
spark voltage) on outputs material removal
rate(MRR), surface roughness(SR) and wire
wear ratio(WWR) using optimizing techniques
such as TOPSIS and PCA-TOPSIS methods.
 INTRODUCTION

• Wire electrical discharge machining (WEDM) is

one of the important non-traditional machining
processes which is used for machining difficult
to cut materials like composites and inter
metallic materials ex: Titanium.
• Intricate profiles used in prosthetics and
biomedical applications can also be done in
WEDM. WEDM involves complex physical and
chemical process including heating and cooling.
WEDM at CPAT Vijayawada
WORKING PRINCIPLE
• Wire electrical discharge machining (EDM) is a non-traditional
machining process that uses electricity to cut any conductive
material precisely and accurately with a thin, electrically
charged copper or brass wire as an electrode.

• During the wire EDM process, the wire carries one side of an
electrical charge and the workpiece carries the other side of
the charge. When the wire gets close to the part, the
attraction of electrical charges creates a controlled spark,
melting and vaporizing microscopic particles of material.

• The spark also removes a miniscule chunk of the wire, so after

the wire travels through the work piece one time, the
machine discards the used wire and automatically advances
new wire.
 MATERIAL
• Titanium is known for it’s high strength,
lightweight, and exceptional corrosion
resistance. Despite being as strong as steel,
titanium is about 40 percent lighter in weight,
which, along with its resistance to cavitation
and erosion, makes it an essential structural
metal for aerospace engineers.
 1.4 MULTI CRITERIA DECISION
MAKING:
• Multiple criteria decision making (MCDM) refers
to making decisions in the presence of multiple,
usually conflicting, criterias.
• The Multi criterion Decision-Making (MCDM) are
gaining importance as potential tools for
analyzing complex real problems, due to their
inherent ability to judge different alternatives on
various criteria for possible selection of the
best/suitable alternative (s).
• Some these methods are ELECTRE, Goal
Programming, Grey Relational Analysis, TOPSIS,
Fuzzy based MCDM methods etc.
 LITERATURE REVIEW

References:
• Multiple process parameter optimization of
wire electrical discharge machining on Inconel
825 using Taguchi grey relational analysis
G. Rajyalakshmi & P. Venkata Ramaiah
• Mahapatra SS, Patnaik A (2006) Optimization
of wire electrical discharge machining
(WEDM) process parameters using Taguchi
method. Int J Adv Manuf Technol 34:911–925
• Sagar, P.B., Pantanwane, P.D., & Rajiv, B. (2014).
Optimisation of hard turning of M42 tool steel
using PCA-TOPSIS method. Proceedings of 5th
International & 26th All India Manufacturing
Technology, Design and Research Conference
(AIMTDR 2014), No.325, pp.1-6.
• Tian- Syung Lan (2009). Taguchi optimization of
multi-objective CNC machining using TOPSIS.
Information Technology Journal, Vol.8(6), pp.917-
922.
 PROBLEM FORMULATION
• The problem is to find the optimum machining parameters
for high metal removal rate , minimum surface roughness
and minimum wire wear ratio of the Wire electric discharge
machine (WEDM).

• Optimization of machining parameters are must to avoid

wastage of valuable raw materials, equipment and money.

• In this study Pulse on time, Pulse of time, Input current and

spark voltage at 3 levels are considered. taguchi design of
experiments is applied up on to obtain optimum results.

• 9 experiments should be conducted and Material removal

rate (MRR) ,Surface roughness(SR) and Wire wear ratio are
to be calculated.
 EXPERIMENTAL WORK

• Titanium bar (Grade 4)

EXPERIMENTAL WORK

WEDM Machining process in WEDM

Titanium bar after machining Specimens collected after machining

KERF = (length of block- length of specimen)/2

(mm)

Tool makers microscope(0.001 mm

Material removal rate is calculated as:

MRR = Vc × b × h mm³ / min

Where:

V = Cutting speed in millimeters per minute

b = Width of cut in millimeters (kerf)

h = Height of the workpiece in millimeter

 Surface measurement device
(Talysurf surface measurement device)
Contact type a measurement stylus across the
surface , profilometers.
 Micro weighing machine

W.W.R =Initial weight of wire- final weight of wire

Initial weight of wire
 EXPERIMENTATION DESIGN AND
OPTIMIZATION TECHNIQUES
ORTRHOGONAL ARRAYS
• In selecting an appropriate OA, the following
prerequisites are required:
• Selection of process parameters and/or their
interactions to be evaluated.
• Selection of number of levels for the selected
parameters. The following steps can be
followed for designing an OA experiment
(Matrix experiment) (krishnaiah, 2012):
Standard orthogonal arrays
 SELECTION OF OA AND PARAMETER
ASSIGNMENT
• In experimentation, Taguchi’s single level
design was selected as it was decided to keep
four parameters that are being studied at three
levels.
• The selected process and tool parameters and
their levels are given in above Table .Four three
level parameters have 8 DOF, i.e., the total DOF
required will be 8 [4×2].
• The most appropriate orthogonal array in this
case is L9 (34) OA with 8 = [9-1] DOF.
 Technique for Order Preference based
Similarity to Ideal Solution (TOPSIS)
• STEP-1: Obtain the evaluation matrix consisting
of ' q' alternatives and ' p' criteria (responses),
with the intersection of each alternative and
criteria given as given as xji .
• STEP-2: Obtain normalized data matrix, R using
the relationship.
• STEP-3: Obtain the weighted decision matrix, V by
multiplying each column of R by the corresponding
weight.
• Step-5: Calculate the separation measures.
The separation of each alternative from the ideal
solution ( sj+ ) is given as follows:
• Step-6: Calculate the relative closeness of various
alternatives to the ideal solution,
which is considered as the C *.
• Ideal solution is a point which is best of everything
& Negative ideal solution is point where all the
worst exists.
ANALYSIS AND RESULTS Of TOPSIS
VALUES FOR TOPSIS METHOD
 PRINCIPAL COMPONENT ANALYSIS BASED TOPSIS
(PCA-TOPSIS)
Step-1:
• Before performing PCA depending on the type of response
desired calculate S /N ratio using formulae given below:
• Step-2: Normalize the S / N ratio of each
response variable using the following equation.
• Step-3: Find correlation matrix for the
normalized responses.
• Step-4: Perform Bartlett’s sphericity test on raw
response data.
• Bartlett’s spericity test:
• H0 (null hypothesis): Correlation matrix of
responses is equal to identity matrix.
• H1 (Alternate hypothesis): Correlation matrix of
responses is not equal to identity matrix.
• Step-5: Conduct PCA on normalized S/N ratios of
response variables and obtain the eigen values,
and eigen vectors and proportion of variance
explained by different principal components.
• Procedure to conduct PCA:
• Solve the characteristic equation, /S -λI/ = 0.
Where,
• Once the eigen values l’s are determined proportion of
variance explained by each PC (Principal Component) and
cumulative variance can also be calculated.
• From the eigen values, the eigen vector for each eigen
value ( l ) can be computed by solving,
• Step-6: Determine the number of principal
components retained. The number of principal
components retained should account for 100%
variation in the original values.
• For extracting PC‟s there different methods they
are listed below:
• Cumulative percentage of total variance

• Step-7: Develop the variation mode charts and

determine the optimization direction of the
selected principal components.
• Step-8: Calculate principal component scores
from eigenvectors using the formula given below.
• Step-9: Establish a normalized matrix, where 'q' trials are the
possible alternatives for all the principal components. The
normalized matrix for j th trial and l th principal component score is
evaluated using formula given below.
• Step-13: Calculate the relative closeness of various
alternatives to the ideal solution, which is
considered as the C . Ideal solution is a point which
is best of everything & Negative ideal solution is
point where all the worst exists.
PRINCIPAL COMPONENT ANALYSIS BASED TOPSIS
RESULTS

Correlation matrix
Values for PCA-TOPSIS method
Values for PCA-TOPSIS method
 CONCLUSIONS AND RECOMMENDATIONS FOR
FUTURE WORK
• 1. Principal component analysis method takes care of
correlation perfectly and leads to the best optimal
solution when combined with TOPSIS.
• 2. By using TOPSIS Techniqe the 8th trail is the best among
other. The optimal setting of the parameters Pulse on
time Ton=110 µs , Pulse off time Toff=60 µs, Input
current Ip =11 amps, Spark voltage Sv= 20 volts
• 3. By using PCA- TOPSIS Technique 9th trail stands as the
best . The optimal setting of the parameters Pulse on time
Ton =110 µs , Pulse off time Toff=55 µs, Input current
Ip =11amps, Spark voltage Sv= 10 volts
• 4.Both the TOPSIS, PCA- TOPSIS gives the optimum
machining parameters.
 RECOMMENDATIONS FOR FUTURE WORK

• 1. By varying the machining parameters on the

same material the effects of responses can be
studied.
• 2. By varying the work piece material and
considering the process and tool parameters
responses can be optimized.
• 3. Combine PCA with other techniques and find
the which gives best optimum