Front. Mech. Eng.
2013, 8(3): 319–332
DOI 10.1007/s11465-013-0269-3
RESEARCH ARTICLE
Ravindra Nath YADAV, Vinod YADAVA, G.K. SINGH
Multi-objective optimization of process parameters in Elec-
tro-Discharge Diamond Face Grinding based on ANN-NSGA-II
hybrid technique
© Higher Education Press and Springer-Verlag Berlin Heidelberg 2013
Abstract The effective study of hybrid machining
processes (HMPs), in terms of modeling and optimization
has always been a challenge to the researchers. The
combined approach of Artificial Neural Network (ANN)
and Non-Dominated Sorting Genetic Algorithm-II
(NSGA-II) has attracted attention of researchers for
modeling and optimization of the complex machining
processes. In this paper, a hybrid machining process of
Electrical Discharge Face Grinding (EDFG) and Diamond
Face Grinding (DFG) named as Electrical Discharge
Diamond face Grinding (EDDFG) have been studied
using a hybrid methodology of ANN-NSGA-II. In this
study, ANN has been used for modeling while NSGA-II is
used to optimize the control parameters of the EDDFG
process. For observations of input-output relations, the
experiments were conducted on a self developed face
grinding setup, which is attached with the ram of EDM
machine. During experimentation, the wheel speed, pulse
current, pulse on-time and duty factor are taken as input
parameters while output parameters are material removal
rate (MRR) and average surface roughness (Ra). The
results have shown that the developed ANN model is
capable to predict the output responses within the
acceptable limit for a given set of input parameters. It
has also been found that hybrid approach of ANN-NSGA-
II gives a set of optimal solutions for getting appropriate
value of outputs with multiple objectives.
Received April 17, 2013; accepted May 12, 2013
✉
Ravindra Nath YADAV ( ), Vinod YADAVA, G.K. SINGH
Department of Mechanical Engineering, Motilal Nehru National
Institute of Technology, Allahabad-211004, India
E-mail: rnymnnit@yahoo.com
G.K. SINGH
Department of Mechanical Engineering, Galgotias University, Gr.
Noida, India
Keywords hybrid machining processes (HMPs), electri-
cal discharge diamond grinding (EDDG), artificial neural
network (ANN), genetic algorithm, modeling and optimiza-
tion
1 Introduction
Recently, hybrid machining processes (HMPs) are show-
ing potential applications for the machining of the difficult
to machine materials such as high temperature resistant
steels, super alloys, wear resistant ceramics and multi
functional qualities composites. Basically, HMPs are
combination of two or more (conventional or unconven-
tional) machining processes, whose performances are
better than the sum of the constituent machining processes
when they are individually applied [1,2]. The main aims of
HMPs are utilizing the advantages and at the same time to
avoid or reduce the disadvantages of constituent processes.
Generally, HMPs are classified into two groups: colla-
borative and cooperative. In collaborative HMPs: the one
machining process is directly involved in material removal
while the other machining processes either assist in
material removal or facilitate the machining by enhancing
the main process. These HMPs are assisted by different
techniques such as ultrasonic vibration, magnetic field,
laser beam or plasma beam. In cooperative HMPs: all the
constituent processes are directly involved into material
removal activities. These processes are mainly developed
by combining the abrasive grinding process with most
widely used unconventional machining processes such as
electrical discharge machining (EDM) and electro-
chemical machining (ECM) process in different
configurations.
In various HMPs, the abrasive action based HMPs are
widely acceptable in the modern manufacturing industries
due to their better performance over the conventional and
non-conventional machining processes. These HMPs are
320 Front. Mech. Eng. 2013, 8(3): 319–332
Electro-Discharge Abrasive Grinding (EDAG), Electro-
Chemical Abrasive Grinding (ECAG) and Electro-Chemi-
cal-Discharge Abrasive Grinding (ECDAG) [3]. When the
metal bonded diamond wheel is used as an abrasive wheel,
then EDAG process is called as Electrical Discharge
Diamond Grinding (EDDG) process. The EDDG process
has been developed in three different grinding configura-
tions, which is shown in Fig. 1. These configurations are:
Electrical Discharge Diamond Cut-off Grinding
(EDDCG), Electrical Discharge Diamond Face Grinding
(EDDFG) and Electrical Discharge Diamond Surface
Grinding (EDDSG).
The different configurations of EDDG process are used
to create different features on workpiece surface with
application of either face or circumference of metal bonded
diamond wheel. The EDDCG configuration is used to cut
workpiece into pieces or making grooves into workpiece
using abrasion and sparking actions at peripheral surface of
the grinding wheel. The EDDFG configuration is used for
machining end surface of workpiece using abrasion and
sparking at face surface of grinding wheel. The EDDSG
configuration is used for machining the flat surface using
abrasion and sparking at peripheral surface of grinding
wheel. All the configurations of EDDG process need a
rotating metal bonded diamond grinding wheel with a
provision of spark generation mechanism of the EDM
process.
EDDFG configuration has been developed by combin-
ing the Electrical Discharge Face Grinding (EDFG) and
Fig. 1 Different configurations of EDDG process
Fig. 2 EDDFG as combination of EDFG and DFG
Diamond Face Grinding (DFG) processes, which is shown
in Fig. 2. In this process, metal bonded diamond grinding
wheel rotates about its vertical spindle axis and fed
downward direction toward machine table. The gap
between rotating metal bonded diamond wheel and
workpiece is controlled by servo mechanism of the EDM
machine. The metal bonded diamond wheel and workpiece
are physically separated by inter electrode gap (IEG),
which is filled with dielectric fluid. The spark is generated
between metallic bond of diamond wheel and workpiece,
when DC pulse power supply is applied to the EDM
machine. Due to the spark, the workpiece material is
melted and softened, which is removed by spark erosion
and abrasion actions. In this process, the workpiece is
simultaneously influenced by electrical discharge of EDM
process and abrasive abrasion by diamond particles.
Hence, the material is removed by combined effect of
spark erosion and abrasive abrasion. The main advantages
of this process are: higher material removal rate (MRR)
with good surface finish, requirement of low grinding
forces, online dressing of diamond grinding wheel and
continuous removal of recast layer with micro cracks on
machined surface.
Most of the experimental research works on EDDG
process are related to the cut-off grinding configuration [4–
12]. Aoyama and Inasaki [4] applied EDDG process in cut-
off mode for machining of cemented carbide using resin
bonded diamond wheel. They experimentally studied the
effect of input process parameters such as voltage, pulse