International Journal of Mechanical Engineering and Technology (IJMET)

Volume 6, Issue 9, Sep 2015, pp. 01-09, Article ID: IJMET_06_09_001

Available online at
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ISSN Print: 0976-6340 and ISSN Online: 0976-6359
IAEME Publication
________________________________________________________________________

SELECTION OF OPTIMUM PARAMETERS

FOR MRR & SR SIMULTANEOUSLY IN
AWJM OF INCONEL-625 ALLOY USING
TOPSIS METHOD
G Venkata Kishore
M. Tech-CAD/CAM Student, Dept. of Mechanical Engineering,
Siddarth Institute of Engineering and Technology,
Narayanavanam, Puttur, India,
F Anand Raju
Professor, Dept. of Mechanical Engineering,
Siddarth Institute of Engineering and Technology,
Narayanavanam, Puttur, India
ABSTRACT
Inconel 625 has a wide range of applications because of its high resistance
to corrosion cracking, pitting, crevice formation and to a variety of mineral
and organic acids along with high thermal fatigue resistance. However
conventional machining of Inconel 625 is not so economical and ease, on the
other hand non conventional processes like laser cutting, abrasive water jet
machining(AWJM), electric discharge machining(EDM), etc have a very good
potential in overcoming these machining difficulties. Among these AWJM is
commonly employed for very hard and brittle materials due to its economical
and technical significance.
In this paper, research oriented experimentation of the AWJM of Inconel
625 is planned and carried out successfully to optimize the input process
parameters for fine Surface finish (SR) and high Material removal rate
(MRR). Optimization was carried out in two phases, in the first phase SR and
MRR are individually optimized as per Taguchi method, in the second phase
Taguchis philosophy is combined with TOPSIS method for the simultaneous
optimization of SR and MRR. S/N ratios, Means, Regression equations, etc
with their corresponding graphs are generated and provided in the following
sections.
Key words: AWJM, Inconel 625, MRR, SR, Taguchi integrated with TOPSIS
method.

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G Venkata Kishore and F Anand Raju

Cite this Article: G Venkata Kishore and F Anand Raju, Selection of

Optimum Parameters For MRR & SR Simultaneously In AWJM of Inconel625 Alloy Using Topsis Method. International Journal of Mechanical
Engineering and Technology, 6(9), 2015, pp. 01-09.
http://www.iaeme.com/currentissue.asp?JType=IJMET&VType=6&IType=9

1. INTRODUCTION
Inconel 625 is one among the family of austenite nickel-chromium-based super alloys
which are having high resistance to corrosion and stabilized mechanical properties
even at extreme temperatures. Specifically In conel 625 is highly resistant to inter
crystalline corrosion, pitting, crevice corrosion, chloride induced stress corrosion
cracking and oxidative stress at high temperatures of up to 10500C.Hence it is
employed for the manufacture of components that are in continuous exposure to sea
water and high mechanical stresses such as oil and gas extraction machinery,
aerospace industry, marine appliances, chemical processing, nuclear reactors,
pollution control equipment etc. As the alloy is having high strength and work
hardening nature it cannot be machined with conventional machining processes.
Therefore non conventional machining techniques like Laser cutting and abrasive
water jet machining etc are employed. From economic perspective laser cutting is
very good for cutting Inconel 625 plates of upto 4mm thick, for Inconel-625 plates
beyond 4mm thick AWJM is commonly used. Further AWJM has the capability of
machining the least slot widths over the complex components.
Extensive studies over optimization of AWJM of grey cast iron, aluminium,
composites, steel, hard polymers and tiles reveals that water pressure and abrasive jet
treverse speed are the significant factors influencing MRR on the othe hand water
pressure and abrasive flow rate mostly determine the quality of surface finish.
Remaining parameters like abrasive grit size and stand off distance are sub significant
in determining MRR and SR. It was observed that comparitively high abrasive flow
rates are required for ferrous materials followed by non ferrous materials and hard
polymers. Till now optimization of AWJM parameters for Inconel 625 did not gained
much attention despite the prevalence of AWJM of Inconel-625. So the present work
concentrates on the optimization of AWJM parameters for good MRR and SR based
on Taguchi method combined with TOPSIS multicriterian optimization technique. In
this work, Water pressure, stand off distance, abrasive jet traverse speed and abrasive
flow rate were optimized for two quality characteristics namely material removal rate
(MRR) and surface roughness (SR). Optimized values are predicted based on the
results obtained from ANOVA, F-tests, Signal To Noise Ratios and Closeness
Coefficient (CCi) of TOPSIS method. Further regression equations are generated
through Regression Analysis.

2. EXPERIMENTAL WORK
2.1. Work Material
In the present work Inconel 625 alloy plate of 300mm*150mm*15mm was taken to
perform the experiments as per Taguchis DOE.

2.2. Machine Details

The experiments are performed at ALIND Pvt. Ltd which is the leading AWJM
workshop in Chennai (T.N). KMTs Streamline SL-V 50 Classic ultra high pressure

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Selection of Optimum Parameters for MRR & SR Simultaneously In AWJM of Inconel-625

Alloy Using Topsis Method

intensifier pump fitted with a CNC cutting bed and variable abrasive feeding system
was used for this research work.
Table 1 Machine specifications
S.No
1
2
3
4
5
6
7
8
9
10

Parameter
Dimentions of pump
Table size
X-Axis
Y-Axis
Z-Axis
Ultra high pump
Max water pressure
Orifice diameter
Number of nozzles
Abrasive flow rate (Garnet Sand)

Specification
1700 mm X 1500 mm X 1400 mm
1500 mm X 3000 mm
1500 mm
3000 mm
210 mm
50 HP
55,000 psi (3,800 bar)
0.35 mm
1
100 700 gms/min

2.3. Process Parameters

2.3.1. Constant parameters
The parameters as given in Table 2 are kept constant throught the experimentation.
Table 2 Constant Parameters
Abrasive type
Abrasive size
Orifice dia
Nozzle dia
Nozzle length
Work piece thickness
Jet impact angle
Avg dia of abrasives

Garnet Sand
80 Mesh
0.35 mm
1.05 mm
76.2 mm
15 mm
900
0.18 mm

2.3.2. Variable parameters and their range

Input Parameters as given in Table 3 are varied within their maximum feasible range
to generate Taguchis L9 Orthogonal Array.
Table 3 Variable Process Parameters
Symbol
PRE
SOD
AFR
JTS

Control Factor
Water pressure (MPa)
Stand off distance (mm)
Abrasive flow rate (gm/min)
Jet traverse speed (mm/min)

Level 1
230
2
300
84

Level 2
300
5
400
147

Level 3
370
8
500
210

2.4. Measuring MRR and SR

2.4.1. MRR measurement
The work piece is first weighted with the balancing machine and then kept on the rack
of the working table. After cutting the work piece, its weight is measured again for
finding out the difference in weights, which is used to calculate the material removal
rate.

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G Venkata Kishore and F Anand Raju

2.4.2. Surface finish measurement

Talysurf SJ-201P: Talysurf SJ-201P (Portable surface roughness tester) instrument
was used to measure the surface roughness values at different cross-section of the
cuts.

2.5. Experimental procedure

Practical experiments are conducted as per Taguchis OA. Since we are opting for 4
parameters each variable at 3 different levels, as per Taguchis DOE a L9 Orthogonal
array is best suited for 4x3 design. Therefore vertical cuts are made over the work
piece by varying the parameter settings in accordance with the OA given in Table 4,
for this purpose water pressure is varied at a separate manual console provided in the
KMT Streamline SL-V pump hose, remaining three parameters are varied at the CNC
console provided near the machining bed.

3. OPTIMIZATION
Simultaneous mode of optimization followed here consists two stages of optimization.
In the first stage individual characteristics i.e.MRR followed by SR are optimized one
by one saperately as per Taguchi philosophy and two optimized parameter settings are
predicted one each for MRR and SR respectively. In the second stage both the quality
characteristics i.e.MRR and SR are taken simultaneously to calculate the
CLOSENESS COEFFICIENT(CCi) as per TOPSIS method. This CCi is again
optimized as per Taguchi analysis to generate a input parameter combination such that
the generated combination represents a simultaneous optimized setting for both the
quality characteristics MRR and SR.

3.1. Optimization of individual quality characteristics

3.1.1. Material removal rate (MRR)
For the purpose of optimising MRR, Taguchi analysis is carried out using MINITAB
16.1 software.
Table 4 L9 OA with observed MRR and generated S/N ratios and Means
Trial
No.
1
2
3
4
5
6
7
8
9

Result /
observed value

Control Parameter (Levels)

PRE
(Mpa)
230
230
230
300
300
300
370
370
370

SOD
(mm)
2
5
8
2
5
8
2
5
8

AFR
(gm/min)
300
400
500
400
500
300
500
300
400

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JTS
(mm/min)
84
147
210
210
84
147
147
210
90

MRR(g/min)
37.37
40.83
42.22
39.52
42.76
38.16
40.45
41.84
45.34

Taguchi Analysis
S/N
Ratios
31.4505
32.2196
32.5104
31.9363
32.6208
31.6322
32.1384
32.4318
33.1296

Means
37.37
40.83
42.22
39.52
42.76
38.16
40.45
41.84
45.34

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Selection of Optimum Parameters for MRR & SR Simultaneously In AWJM of Inconel-625

Alloy Using Topsis Method
Table 5 Response table of mean S/Nratio for MRR
Level

Pressure

SOD

AFR

JTS

31.84

32.06

31.84

32.40

32.43

32.06

32.42

32.00

32.42

32.57

32.42

32.29

Delta

0.59

0.51

0.58

0.40

Rank

Main Effects Plot for SN ratios

Data Means

Pressure

32.6

SOD

32.4

Mean of SN ratios

32.2
32.0
31.8
230

300

370

AFR

32.6

JTE

32.4
32.2
32.0
31.8
300

400

500

84

147

210

Signal-to-noise: Larger is better

Figure 1 Main effects plot for S/N ratios of MRR

3.1.2. Surface roughness (SR)

SR values are also analysed and optimized in the same manner as that of MRR and
the generated results are given below in the form of tables and graphs.
Table 6 L9 OA with observed SR and generated S/N ratios and Means
Trial
No.

PRE
(Mpa)

Control Parameter (Levels)

SOD
AFR
JTS
(mm) (gm/min) (mm/min)

Resut/ Observed value

Surface roughness (m)
1
2
3
Avg

Taguchi Analysis

230

300

84

0.97

1.21

1.10

1.09

S/N
ratios
-0.74853

230

400

147

0.79

0.95

1.14

0.98

0.26457

0.97

230

500

210

0.86

0.97

1.01

0.95

0.44553

0.95

300

400

210

1.09

1.12

1.24

1.15

-1.21396

1.15

300

500

84

1.05

1.19

1.06

1.10

-0.82785

1.10

300

300

147

1.51

1.28

1.35

1.38

-2.79758

1.38

370

500

147

0.96

0.92

0.92

0.93

0.63034

0.93

370

300

210

1.04

0.99

1.02

1.02

-0.17200

1.02

370

400

90

0.81

0.90

0.84

0.85

1.41162

0.85

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Means
1.09

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G Venkata Kishore and F Anand Raju

Table 7 Response table of mean S/Nratio for SR
Level
1
2
3
Delta
Rank

Pressure
-0.012
-1.613
0.623
2.236
1

SOD
-0.444
-0.245
-0.313
0.198
4

AFR
-1.239
0.154
0.082
1.393
2

JTS
-0.054
-0.634
-0.313
0.579
3

Main Effects Plot for SN ratios

Data Means

Pressure

SOD

0.5
0.0

Mean of SN ratios

-0.5
-1.0
-1.5
230

300
AFR

370

5
JTS

300

400

500

84

147

210

0.5
0.0
-0.5
-1.0
-1.5

Signal-to-noise: Smaller is better

Figure 2 Main effects plot for S/N ratios of SR

3.2. Simultaneous optimization by TOPSIS method

Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) method was
stated in the year 1995 by Hwang and Yoon. References provided at the end will
explain the detailed step by step of TOPSIS. Here only the end resulted tables are
provided due to a constraint on total no. of pages.
Table 8 Decision Matrix (DM)
S.No
MRR
SR

1
37.37
1.09

2
40.83
0.97

3
42.22
0.95

4
39.52
1.15

5
42.76
1.10

6
38.16
1.38

7
40.45
0.93

8
41.84
1.02

9
45.34
0.85

Table 9 Normalised DM (NDM)

S.No
MRR
SR

1
0.303
0.328

2
0.332
0.313

3
0.343
0.343

4
0.321
0.349

5
0.347
0.334

6
0.310
0.411

7
0.328
0.280

8
0.340
0.292

9
0.368
0.331

7
0.164
0.140

8
0.170
0.146

9
0.184
0.165

Table 10 Weighted NDM (WNDM)

S.No
MRR
SR

1
0.152
0.164

2
0.165
0.156

3
0.171
0.171

4
0.160
0.174

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5
0.173
0.167

6
0.155
0.205

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Selection of Optimum Parameters for MRR & SR Simultaneously In AWJM of Inconel-625

Alloy Using Topsis Method
Table 11 Saperation Measures
S.No
Si+
Si-

1
0.040
0.041

2
0.024
0.051

3
0.033
0.039

4
0.027
0.032

5
0.028
0.044

6
0.071
0.003

7
0.019
0.066

8
0.015
0.623

9
0.025
0.041

7
0.086
0.770

8
0.077
0.802

9
0.066
0.621

Table 12 Closeness Coefficient (CCi)

S.No
Si+ + SiCCi= Si- /
(Si+ + Si-)

1
2
0.082 0.075
0.509 0.675

3
0.073
0.539

4
0.059
0.544

5
0.073
0.607

6
0.074
0.042

Table 13 L9 OA of CCi with generated S/N ratios and Means

Exp No
1
2
3
4
5
6
7
8
9

PRE
230
230
230
300
300
300
370
370
370

SOD

AFR
300
400
500
400
500
300
500
300
400

2
5
8
2
5
8
2
5
8

JTS
84
147
210
210
84
147
147
210
84

CCi
0.509145
0.675223
0.539553
0.544465
0.607172
0.042817
0.770740
0.802058
0.621040

S/N Ratio
-5.8632
-3.4111
-5.3593
-5.2806
-4.3338
-27.367
-2.2618
-1.9159
-4.1376

MEAN
0.509145
0.675223
0.539553
0.544465
0.607172
0.042817
0.770740
0.802058
0.621040

Table 14 Response table of mean S/N ratio for CCi

Level
1
2
3
Delta
Rank

Pressure
4.878
12.327
2.772
9.556
1

SOD
4.469
3.220
12.288
9.068
2

AFR
11.716
4.276
3.985
7.731
3

JTS
4.778
11.014
4.185
6.828
4

Main Effects Plot for SN ratios

Data Means

Pressure

SOD

-4

Mean of SN ratios

-6
-8
-10
-12
230

300
AFR

370

5
JTS

300

400

500

84

147

210

-4
-6
-8
-10
-12

Signal-to-noise: Larger is better

Figure 3 Main effects plot for S/N ratios of CCi

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4. RESULTS AND DISCUSSION

Hence simultaneous optimization of AWJM parameters of Inconel 625 has been
successfully carried out and the optimized process parameters are presented below
Table 15 Predicted optimum parameter setting for SR
Parameter

Level Description

Level

Water Pressure
Stand of Distance
Jet traverse speed
Abrasive flow rate

300
2
147
300

2
1
2
1

Confirmation experiments were conducted with the above parameter setting and a
Surface roughness value of 0.72m was realised.
Table 16 Predicted optimum parameter setting for MRR
Parameter
Pressure
Stand of Distance
Jet traverse speed
Abrasive flow rate

Level Description
370
5
84
400

Level
3
2
1
2

Confirmation experiments were conducted with the above parameter setting and a
MRR of 44.32gms/min was realised.
Table 17 Predicted optimum parameter setting for combined SR and MRR
Parameter
Pressure
Stand of Distance
Jet traverse speed
Abrasive flow rate

Level Description
370
5
210
500

Level
3
2
3
3

Confirmation experiments were conducted with the above parameter setting, SR

and MRR values of 0.83m and 42.54gms/min are obtained respectively.

4.1. Regression Equations

MRR = 28.8 + 0.0172 Pressure + 0.466 SOD + 0.0134 AFR - 0.0050 JTS
SR = 1.36 - 0.000643 Pressure + 0.0239 SOD - 0.000417 AFR - 0.000079 JTS
CCi = - 0.029 + 0.00112 Pressure - 0.0345 SOD + 0.000939 AFR + 0.00039 JTS

5. CONCLUSION
Among various methods of simultaneous optimization for conventional and non
conventional machining, the method (TOPSIS) was studied and applied in this
research work because of its flexibility with no requirement of calculating complex
domain formulations or simulation of the process with a computer, as these tasks
would require a lot of hardware and time for determining the optimum, via TOPSIS
one can find the optimum solution for a complex problem with very simple statistical
calculations that can be made with a scientific calculator. This approach also gives
much more reliable solutions as exact experimental values are used to represent the
process. The experimental result for optimum setting shows that there is a
considerable improvement in the performance characteristics. Thus the multiobjective
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Selection of Optimum Parameters for MRR & SR Simultaneously In AWJM of Inconel-625

Alloy Using Topsis Method

approach using TOPSIS with Taguchi approach is capable of solving any type of
optimization problem.

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