Abstract
Superalloys are categorized as difficult to process materials with a broad spectrum of applications in industries. Process modeling and optimization of WEDM performances on nickel- and titanium-based superalloys are widely investigated. However, such investigations on iron-based superalloy are still lacking and hence probed in the present article. Thus, the paper targets modeling the correlation between the performance parameters and the control parameters with two popular techniques: response surface methodology (RSM) and artificial neural network (ANN) for WEDM of a typical iron-based superalloy, i.e., A286 superalloy. A comparison between the model estimates and the experimental values is made to check ANN and RSM's prediction accuracy. The estimates by the ANN model are exact and consistent with the experimental results. An analysis of variance (ANOVA) test is performed to perceive the degree of statistical significance of parameters. Moreover, a novel two-stage procedure, i.e., MOEA/D in collaboration with TOPSIS method, is implemented to search the optimal condition for process performances. The quality of Pareto-optimal solutions acquired using MOEA/D is compared to that of Pareto-optimal solutions obtained using NSGA II, PESA II, and MMOPSO through the use of a hypervolume (HV) parameter. Wilcoxon’s test is performed to identify the statistical difference between MOEA/D and competing algorithms. The optimal parametric combination recommended by the proposed optimization approach is Ton = 130 µs, Toff = 52 µs, Ipeak = 12 A, Wf = 5 m/min and SV = 30 V. The proposed optimization technique can also be exploited in other manufacturing processes.
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Abbreviations
- WEDM:
-
Wire electric discharge machining
- MRR :
-
Material removal rate
- SR :
-
Surface roughness
- T on :
-
Pulse-on time
- T off :
-
Pulse-off time
- I peak :
-
Peak current
- W f :
-
Wire feed rate
- SV:
-
Servo voltage
- Cs:
-
Cutting speed
- L :
-
Plate thickness
- \(\lambda_{c}\) :
-
Cutoff length
- MOEA:
-
Multi-objective evolutionary algorithm
- MOEA/D:
-
Multi-objective evolutionary algorithm based on decomposition
- MOP:
-
Multi-objective optimization problem
- NSGA II:
-
Non-dominated sorting genetic algorithm II
- PESA II:
-
Pareto-envelope-based selection algorithm II
- MMOPSO:
-
Multi-objective particle swarm optimization
- HV:
-
Hypervolume
- TOPSIS:
-
Technique for order preference by similarity to ideal solution (TOPSIS)
- \(S^{ + }\) :
-
Positive ideal solution
- \(S^{ - }\) :
-
Negative ideal solution
- \(E_{i}^{ + }\) :
-
Separation from the positive ideal solution
- \(E_{i}^{ - }\) :
-
Separation from the negative ideal solution
- \(CC_{i}\) :
-
Relative closeness coefficient
- MCDM:
-
Multiple-criteria decision-making
- RSM:
-
Response surface methodology
- ANN:
-
Artificial neural network
- MLP:
-
Multilayer perceptron
- \(d_{\max }\) :
-
The maximum value of the response parameter
- \(d_{\min }\) :
-
The minimum value of the response parameter
- \(d_{i}\) :
-
The nominal value of the response parameter
- trainlm:
-
Levenberg–Marquardt algorithm
- learngd:
-
Gradient descent learning function
- PBMOO:
-
Preference-based multi-objective optimization
- TLBO:
-
Teaching–learning-based optimization
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Saha, S., Maity, S.R., Dey, S. et al. Modeling and combined application of MOEA/D and TOPSIS to optimize WEDM performances of A286 superalloy. Soft Comput 25, 14697–14713 (2021). https://doi.org/10.1007/s00500-021-06264-5
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DOI: https://doi.org/10.1007/s00500-021-06264-5