This article was downloaded by: [Dalhousie University]

On: 20 August 2013, At: 00:22

Publisher: Taylor & Francis
Informa Ltd Registered in England and Wales Registered Number: 1072954 Registered office: Mortimer House,
37-41 Mortimer Street, London W1T 3JH, UK

Materials and Manufacturing Processes

Publication details, including instructions for authors and subscription information:
http://www.tandfonline.com/loi/lmmp20

Optimization of Material Removal Rate in Micro-EDM

Using Artificial Neural Network and Genetic Algorithms
a a a
K. P. Somashekhar , N. Ramachandran & Jose Mathew
a
Department of Mechanical Engineering, National Institute of Technology, Calicut, Kerala,
India
Published online: 10 Jun 2010.

To cite this article: K. P. Somashekhar , N. Ramachandran & Jose Mathew (2010) Optimization of Material Removal Rate in
Micro-EDM Using Artificial Neural Network and Genetic Algorithms, Materials and Manufacturing Processes, 25:6, 467-475, DOI:
10.1080/10426910903365760

To link to this article: http://dx.doi.org/10.1080/10426910903365760

PLEASE SCROLL DOWN FOR ARTICLE

Taylor & Francis makes every effort to ensure the accuracy of all the information (the “Content”) contained
in the publications on our platform. However, Taylor & Francis, our agents, and our licensors make no
representations or warranties whatsoever as to the accuracy, completeness, or suitability for any purpose of the
Content. Any opinions and views expressed in this publication are the opinions and views of the authors, and
are not the views of or endorsed by Taylor & Francis. The accuracy of the Content should not be relied upon and
should be independently verified with primary sources of information. Taylor and Francis shall not be liable for
any losses, actions, claims, proceedings, demands, costs, expenses, damages, and other liabilities whatsoever
or howsoever caused arising directly or indirectly in connection with, in relation to or arising out of the use of
the Content.

This article may be used for research, teaching, and private study purposes. Any substantial or systematic
reproduction, redistribution, reselling, loan, sub-licensing, systematic supply, or distribution in any
form to anyone is expressly forbidden. Terms & Conditions of access and use can be found at http://
www.tandfonline.com/page/terms-and-conditions
 Materials and Manufacturing Processes, 25: 467–475, 2010
Copyright © Taylor & Francis Group, LLC
ISSN: 1042-6914 print/1532-2475 online
DOI: 10.1080/10426910903365760

Optimization of Material Removal Rate in Micro-EDM Using

Artificial Neural Network and Genetic Algorithms
K. P. Somashekhar, N. Ramachandran, and Jose Mathew

Department of Mechanical Engineering, National Institute of Technology, Calicut, Kerala, India

The present work reports on the development of modeling and optimization for micro-electric discharge machining (
-EDM) process. Artificial
neural network (ANN) is used for analyzing the material removal of -EDM to establish the parameter optimization model. A feed forward
neural network with back propagation algorithm is trained to optimize the number of neurons and number of hidden layers to predict a better
material removal rate. A neural network model is developed using MATLAB programming, and the trained neural network is simulated. When
experimental and network model results are compared for the performance considered, it is observed that the developed model is within the limits
of the agreeable error. Then, genetic algorithms (GAs) have been employed to determine optimum process parameters for any desired output
value of machining characteristics. This well-trained neural network model is shown to be effective in estimating the MRR and is improved using
Downloaded by [Dalhousie University] at 00:22 20 August 2013

optimized machining parameters.

Keywords Artificial neural network (ANN); Genetic algorithms; Micro-electric discharge machining (-EDM); Optimization.

Introduction are not only necessary for a better understanding of the

Electric discharge machining (EDM) has grown over
the last few decades from novelty to a main stream
manufacturing process. It is successfully and widely
applied for the machining of various electrically conducting
materials. Micro-electric discharge machining (-EDM),
the modification of EDM process, has the capacity
to produce complex three-dimensional shapes on any
electrically conductive material regardless of its hardness,
strength, and toughness. The selection of appropriate
machining conditions for the optimum material removal
rate (MRR) during the -EDM process is based on the
analysis related to the process parameters. The parameter
settings specified by the manufacturers are applicable only
for the common engineering materials at macro level. The
settings for new materials such as aluminum alloys are
to be optimized further by experimentation. Optimization
of the -EDM process often proves to be a difficult task
owing to the many regulating machining variables. A single
parameter change will influence the process in a complex
way. The selection of the best combination of the process
parameters for an optimum MRR involves the use of
analytical and statistical methods. The modeling of the
process is also an effective way of solving this tedious
problem.
Several attempts have been made to model the EDM
process [1–4]. Comprehensive, qualitative, and quantitative
analysis of the EDM process at micro level and the
development of models of various performance measures
Received July 14, 2009; Accepted September 25, 2009
Address correspondence to K. P. Somashekhar, Department
of Mechanical Engineering, National Institute of Technology,
Calicut, Kerala 673601, India; Fax: +91495 2287250; E-mail:
Somashekar.kp@gmail.com
467
process but are also very useful in process planning,
process simulation, parametric analysis, optimization, the
verification of the experimental results, and in improving the
process performance. With the integration of optimization
techniques of EDM by developing complex and proper
relationships between output performance and controllable
input variables and coupling the complicated machining
phenomenon of -EDM, an accurate physical modeling of
the -EDM process has not been established yet.
A review of the works to predict the material removal
in EDM is of interest. The best explanation of material
removal mechanism in EDM is by the thermoelectric
theory, as established by extensive experimental studies [5].
Theoretical model for cathode erosion [6], thermoelectric
model [7], emergence of artificial neural network (ANN)
as a highly flexible modeling tool in numerous areas
of the manufacturing discipline [8, 9], use of EDM
in tools and dies industry and its integration within
CIM/CAPP environments [10], ANNs applied for the
prediction of surface finish and dimensional analysis
[11, 12], ANNs for the estimation or prediction of the
material removal rate and the online monitoring of the
process [13], etc., are other prominent reported works.
There are reports on the mechanism of material removal
found as different for different pulse durations and for
different workpiece material properties in EDM [14, 15],
mathematical approaches [16], and surface roughness
empirical models as well as multiple regression analysis [17]
employed for modeling, with too many assumptions during
the procedures, which are far from the actual machining
conditions. The machining process is highly complex
and stochastic due to the growth of the plasma channel,
energy sharing between electrodes, process of vaporization,
formation of recast layer, plasma flushing efficiency, and
temperature sensitivity of the thermal properties of work
 468
materials. These models are expected to perform well under
the stochastic environment of actual machining conditions
without understanding the complex physical phenomena
exhibited in electric discharge machining. To generalize
the experimental results and develop the system model
accurately, neural networks and fuzzy systems are reported
as an alternative approach [18, 19]. Other reported works
[20–27] are aimed at explaining what takes place at
the interelectrode gap, machining characteristics, surface
defects caused by tool electrode by EDM process which
requires further investigation to felicitate the effect of
electric discharge energy. Improving the MRR and surface
quality are still challenging problems that limit the wider
applications of the technology.
As regards the -EDM process, earlier results [28–32]
report that a single parameter change can influence the
process in a complex way, and a detailed study by modeling
is essential to understand the -EDM phenomenon. A series
of mathematical models are devised using design of
experiments techniques combined with multiple linear
Downloaded by [Dalhousie University] at 00:22 20 August 2013
regression equations by performing small number of
experiments to select optimal machining conditions of EDM
process [33]. In order to determine the trends of the process
variations, the selection of best combination of the process
parameters for an optimal MMR, surface roughness, and
overcut; analytical and statistical methodology is necessary.
A new integrated neural network–based approach for the
prediction and optimal selection of process parameters in
die sinking EDM [34] and an optimization of EDM using
simulated annealing [35] too have been suggested.
For new and advanced materials, it is not possible to
use existing models. Experimental investigations are always
required. Due to the complex phenomenon, the prediction
of different responses in a -EDM process is far from
perfection. No literature was found which compares the
models of -EDM using resistance capacitance (RC) pulse
generators and ANN modeling. Thus, the work to describe
the application of ANN to model and optimize the -
EDM process is attempted here. Initially, experiments
involving machining of aluminum at various levels of
input parameters viz. gap voltage, capacitance, feed rate,
and speed are conducted. The second phase involves the
establishment of the model using feed forward neural
network architecture with error back-propagation to model
such a stochastic process. The neural network outputs are
compared with the desired output values and testing error is
calculated. Finally, the developed models are validated with
the other experimental data, which were not used earlier for
developing the model, and genetic algorithm (GA) is used
to optimize the process parameters for any desired output
values of machining characteristics.
Experimentation
Experimental Setup
In order to achieve the objective of this -EDM
work, experiments are conducted on DT 110 multiprocess
Micromachining Center with a RC circuit. RC circuit
ensures low discharge current with high frequency and
thus is suitable for microscale electric discharge machining
process. These studies are to investigate the effects of gap
K. P. SOMASHEKHAR ET AL.
Table 1.—Process parameter and their levels.
Level
Factor Parameter Units −1 0 +1
A Gap voltage Volts 80 115 150
B Capacitance F 0.01 0.1 0.4
C Feed rate m/s 3 6 9
D Speed rpm 300 600 900
voltage, capacitance, feed rate, and speed on the MRR
of aluminium plate 1 mm thick. Tool material is tungsten
carbide of 500 m diameter with EDM-3 synthetic oil as
dielectric medium. By the design of experiments, a total
of 81 experimental runs—three-level four factorial (34 )—
are considered. A randomized experimental run has been
carried out to minimize the error due to machining setup.
Based on earlier test results and working characteristics of
the -EDM machine, the gap voltage, capacitance, feed rate,
and speed were chosen as the independent input parameters.
During these experiments, by altering the values of the input
parameters to different levels, stable states of the machining
conditions have also been specified. Accordingly, the main
experiments were conducted with three levels of all the
parameters considered. The levels of machining parameters
for the experiments are as listed in the Table 1.
For the purpose of determining the MRR volume of
the hole is calculated and is further divided by the actual
machining time to obtain the MRR in terms of mm3 /min.
Artificial neural network
In recent years, the application of artificial intelligence is
tremendous in virtually all fields of engineering. Modeling
and optimization are necessary for the understanding and
control of any process. Precise control is a prerequisite to
achieve improved quality and productivity. ANN plays an
important role in studying the linear and nonlinear problems
in different fields of engineering. Many researchers
attempted to develop models from experimental data using
statistical techniques. As the -EDM process is highly
complex and stochastic in nature, it is very difficult to
predict the output characteristics accurately by mathematical
equations. It is difficult to obtain an analytical model
based on physics of the process. Hence an attempt is
made to model such stochastic processes by ANN approach
based on error back-propagation. One of the advantages
of using neural network approach is that a model can be
constructed very easily based on the given input, and the
output is trained to accurately predict process dynamics.
This technique is valuable in processes where a complete
understanding of the physical mechanism is very difficult
to acquire as in the case of the -EDM process.
The feed forward neural network is composed of many
interconnected artificial neurons, which are grouped into
input, hidden, and output layers. The knowledge is presented
by the interconnected weights that are adjusted during
 OPTIMIZATION OF MATERIAL REMOVAL RATE 469

learning stage. The output at any neuron at any layer is

calculated by

n
Yj = f wij xi + j  (1)
i=1

where
Yj = final output from jth neuron
f = activation function (here tansig transfer function
has been used)
n = number of neurons in the previous layer
wij = synaptic weight between ith and jth neuron
xi = output from ith neuron
j = bias at jth neuron.
Figure 1.—Configuration of proposed neural network.
The back-propagation learning technique involves two
phases. One is the forward phase that occurs when an input
is presented and propagated through the neural networks to The network consists of an input layer, variable number
compute an output for each neuron. Hence an error between of hidden nodes/neurons, and an output layer. The input
layer receives information from the external source (data),
Downloaded by [Dalhousie University] at 00:22 20 August 2013

the desired output, Tj , and the actual output, Yj , is computed.

Based on the least squares approach, the quadratic error which is subsequently modified by interconnecting weights
function (Ej ) between the actual outputs and the network between it and the adjacent hidden layers. The sum
outputs is calculated by the formula of the modified signal is then incorporated upon by a
suitable transfer function, and these activated values in turn
1
become the starting signal for the next adjacent layer. In
Ej = T − Yj 2  (2) this way, the modified signal finally reaches the output
2 j j
layer where deviations (error) of the predicted outputs from
the desired outputs are calculated. The input and output
The weights are updated by gradient decent method as patterns sequentially presented to the network for training
follows: and various interconnections are adjusted using error back-
wij p+1 = wij p + 
wij p+1  (3) propagation algorithms. The process is repeated till RMSE
falls below present limiting value [36–38].
Ej
wij p+1 = − + 
wij p  (4) Prediction of MRR
wij
Modeling of the -EDM with feed forward neural
where p is the iteration number,  is a constant real number network is composed of two stages: training and testing of
termed the learning rate, which determines the influence the network with experimental machining data. The scale of
of error over weight changes, and is the momentum the input and output data is an important matter to consider,
coefficient. especially when the operating ranges of process parameters
Back-propagation learning algorithm uses a gradient are different. The scaling or normalization ensures that
search technique to minimize the mean square error of the the ANN will be trained effectively without any particular
output of the network. Mean square is calculated by the variable skewing the results significantly. As a result, all
formula the input parameters are equally important in the training
of network. Mapping of each term to a value between −1
1 1
N
m
1 and 1 is done using the linear mapping formula
MSE = T − Yj 2  (5)
N m i=1 j=1 2 j
R − Rmin Nmax − Nmin 
N = + Nmin  (7)
Tj is the target output of the jth neuron, Yj is the predicted Rmax − Rmin 
value of the jth neuron, N is the total number of training
pattern, and m is the number of output nodes. where N = normalized value of the real variable, R = real
Generally, Root-Mean-Square Error (RMSE) is the value of the variable, Nmin = −1 and Nmax = 1, Rmin and
criterion of convergent error of an ANN. The RMSE can Rmax = minimum and maximum values of the real variables,
be expressed as follows: respectively.
 For improvement on the generalization of a neural
1 1
network, the early stopping technique is used. By this
RMSE = Tj − Yj 2  (6) method the existing data are separated into three subsets.

Tj − Yj
2 j The first subset consists of the training vectors, which
are used to calculate the gradient and to form the weight
The proposed model of neural network architecture is as factors and bias. The second subset is the validation group.
shown in Fig. 1. The error in that group is observed during training, and
 470 K. P. SOMASHEKHAR ET AL.

likewise training group normally decreases during the initial Table 2.—Effect of number of hidden layers on network performance.
phase of training. However, when the network begins to
No of
adjust the data more than needed, the error in that group Error Error (%) RMSE RMSE (%)
layers
raises, and when that increase continues for a certain number
of repetitions, the training stops. Finally, the third subset 1 0006995 −13113 0012511 39348
2 00071142 −04188 0010716 23723
is the test group, and its error is not used during training. 3 00028887 −20109 0010142 48631
It is used to compare the different models and algorithms. 4 00036333 −17725 00089959 44354
In order to use this technique, half of the data were used 5 00001609 −20515 001062 51304
for training, one-fourth for validation, and one-fourth for 6 −00044985 −37715 00093396 82805
7 000080922 −18709 00070638 43775
testing. 8 00042354 −22954 0010798 56072
The selection of data while constituting the three groups 9 −00053874 −40504 00092707 91285
was performed in a stochastic way so that the training 10 −00045085 −47061 0010651 10675
was not performed partially. Batch modes are used for 11 00042996 −088413 0011076 33976
the training of the network. The present network is 12 −00027161 −33733 00093345 73673
13 0010065 −092449 0014148 34639
aimed at establishing the correlation between input process 14 00045006 −14805 00089972 37845
parameters such as gap voltage (V ), capacitance (C), 15 −00041132 −34307 0014432 82116
feed rate (F ), and speed (N ) with process response of 16 0038904 64575 0043049 15138
MRR using suitable network algorithm. Capabilities of 17 0007348 11485 0013907 84138
18 −00063303 −38339 0012948 10124
ANN are governed by characteristics of neurons, network 19 00057199 −43232 0023432 13299
architecture and training algorithm. An attempt is made to −000071737
Downloaded by [Dalhousie University] at 00:22 20 August 2013

20 02107 0018899 65537

study the network performance by optimizing the number
of hidden neurons and hidden layers using neural network
package by neuron solution. Training and Testing
Optimizing the Number of Hidden Nodes and Layers Testing of the trained network is carried out in two phases.
Firstly, it is tested with seen input data sets (training sets).
Selection of number of hidden layers and number In the second phase, the network is tested with unseen input
of neurons in the hidden layers is important in the data sets (testing set). Error value is the numerical difference
optimization of feed forward network with back propagation between the actual value of output and the value predicted
configuration. Too few neurons in the hidden layer can lead by the trained network. The prediction error is expressed as
to under fitting while too many neurons can contribute to
over fitting. Therefore, extensive training and testing of the Experimental value − Prediction value
network architecture for the chosen training test was carried Prediction error (%) =
out by trial and error and by examining generalization Experimental value
capability of the network in which all training points are ×100 (8)
well fit, by changing the hidden layer and number of hidden
neurons. The optimum architecture is found out by varying and mean square error is calculated by Eq. (5) and root
the number of neurons in the hidden layers using MATLAB. mean square error by Eq. (6), which is subsequently used
In this architecture, number of hidden neurons is varied
from 1–20. The connection between nodes is initialized with
random weights. A pattern from the training set is presented Table 3.—Effect of number of hidden neurons on network performance.
into the input layer of the network, and the error at the output
is calculated. The error is propagated backwards—towards No. of
Error Error (%) RMSE RMSE (%)
the input layer—and the weights are updated. The procedure neurons
is repeated for all the training patterns. The weight w and 1 00045147 −31886 0013522 80147
threshold value  are adjusted until the error value comes 2 00079357 −17832 0013867 48247
within the limit. With these values, root mean square error 3 00079878 −21669 001521 54746
4 00063073 −30351 001424 73791
(RMSE) is calculated by using Eq. (6). From Tables 2 and 5 00065014 −29821 0014327 72767
3, it is seen that two hidden layers and six neuron networks 6 00091939 −13651 0014294 39973
has the least RMSE. Therefore, it is proposed to choose 7 00047388 −27307 0012501 65636
six neurons and two hidden layer (4-6-6-1) networks for 8 00047116 −3471 0013609 82211
9 00047096 −34716 0013608 82222
predicting the response. 10 00047087 −34717 0013607 82225
Table 2 shows the effect of number of hidden layers 11 00047096 −34716 0013608 82222
on network performance. Feed-forward network with back- 12 00047095 −34716 0013608 82222
propagation with two hidden layers gave minimum RMSE. 13 00047096 −34716 0013608 82222
14 00047096 −34716 0013608 82222
Table 3 shows the effect of number of hidden neurons 15 00047096 −34716 0013608 82222
on network performance. It is found that network with six 16 00047096 −34716 0013608 82222
hidden neurons gave minimum RMSE. To improve the 17 039475 10307 039496 19892
generalization capability of the network, two layers with six 18 00047336 −3465 0013616 82095
hidden neurons per layer network with back propagation 19 00047096 −34716 0013608 82222
20 00047096 −34716 0013608 82222
algorithm is used to predict the response.
 OPTIMIZATION OF MATERIAL REMOVAL RATE
Figure 2.—Results of neural network training.
Downloaded by [Dalhousie University] at 00:22 20 August 2013
for all the output performance evaluation. The ANN is
trained with optimized number of nodes in the hidden layer.
Figure 2 shows the typical learning behavior of 4-6-6-
1 network. It showed that 50 epochs are good enough to
produce satisfactory results after using 500 epochs in feed-
forward network with back-propagation algorithm training.
The RMSEs of all the three groups when early stopping
technique was applied during the training of the network are
presented in Fig. 2. The network was trained properly by
giving an RMSE of 2.51e-5 and its training took 54 epochs
to complete. From the Fig. 2, it is evident that validation
and testing group RMSEs are higher than that of training
group, as expected. Moreover, they have similar values,
which indicate that the proposed neural network possesses
good generalization ability, thus enabling to model -EDM
process.
Figure 3.—Comparison of experimental and ANN output for MRR for
training set.
471
Figure 4.—Comparison of experimental and ANN output for MRR for test
data set.
Comparison is made for all the training data sets and is as
shown in Fig. 3. The figure indicates that the error is within
the acceptable limit, and hence ANN can be effectively used
for the prediction of MRR in -EDM.
Figure 4 shows that the predictions of MRR in -EDM
process by making use of 4-6-6-1 model are in good
agreement with the experimental results, i.e., the results
indicate that the neural network can very satisfactorily
predict the output data.
Table 4 shows the comparison of ANN results for training
and testing using 4-6-6-1 feed forward network with back
propagation algorithm. The network shows an average
prediction error of 0.8312% for training, and 3.94% while
testing. The performance table shows that the network can
be generalized sufficiently by better capturing the nonlinear
and complex relationships of the process parameters with
performance evaluation. The next step of the work is
to calculate the optimum -EDM process parameters for
maximizing the MRR.
Optimization of process parameters using GA
approach
GAs are computerized search and optimization algorithms
based on mechanics of natural genetics and natural selection
[39–41]. GA mimics the survival of the fittest principle
of nature to make a search process. Fitness function is
first derived from objective function and used in successive
genetic operations. The iteration in GA begins with a
population of random strings representing the design or
Table 4.—Performance of the network.
Average
Sl. Experimental Number of Prediction prediction
No. set experiments error error (%)
1 Training 40 −00031 −08312
2 Testing 20 −00394 −394
 472 K. P. SOMASHEKHAR ET AL.

Table 5.—Optimum process parameters. generations: 500; population size: 20; crossover rate: 0.8;
crossover mechanism: two point; and mutation rate: 0.01;
Process parameters Response
MATLAB is used for the analysis. A number of GA runs has
Gap voltage Capacitance Feed Rate Speed MRR been carried out to identify the range of process parameters
(V ) (F) (m/s) (RPM) (mm3 /min) for optimal performance of -EDM process. The optimum
124.3 0.2007 9 900 0.0842 values of process parameters for which the -EDM process
is expected to offer the best MRR are as shown in Table 5.

decision variables. Thereafter, each string is evaluated to
find fitness value. The population is then operated by three
main operators: reproduction, crossover, and mutation to
create a new population of points. Literature [42–50] also
documents that GA is a better optimization methodology
over the traditional optimization techniques due to its
robustness.
The objective is to maximize the MRR to achieve the
optimal performance
MRR = f V  C F  S
Downloaded by [Dalhousie University] at 00:22 20 August 2013
Discussion
Generating all possible combinations of process
parameters and testing them based on the key design
parameters developed by Design Experts software the
robustness and effectiveness of the optimization techniques
could be examined. The complex nature of the -EDM
process and the effect of interacting process parameters
make the process quite complicated. The resolution of this
factorial design enables the estimation of all the main effects
and interactions.
Figure 5 depicts the plots of various factors effecting

MRR. Increase in capacitance and feed rate results in higher

subject to constraints
80 ≤ V ≤ 150
001 ≤ C ≤ 04  (9)
1 ≤ F ≤ 10
300 ≤ S ≤ 900
where V , C, F , and S are voltage, capacitance, feed
rate, and speed, respectively. The limitations of the input
parameters are assigned according to the electrical capacity
of the experimental setup used, and f represents functional
relationship between MRR and four process parameters.
For each iteration of the GA, MRR values are predicted
by the ANN models for a specified population size.
The GA randomly generated a real valued population of
possible process parameter sets (chromosomes). A new
population for the next generation is created based on old
population using different operator functions viz. number of
MRR. Increase in electrode rotational speed and gap voltage
decreases the MRR. This graphical assessment is one of
the methods, but the accuracy is limited. The combined
effects of gap voltage, capacitance, feed rate, and speed on
MRR are summarized in Fig. 6. The increase in MRR with
increase in capacitance is due to the increase in discharge
energy per pulse. When the energy level is low, the pulse
duration will be less, and heat transfer to the surrounding
media decreases, thereby increasing temperature at the point
of discharge and increase in MRR. At higher voltages, MRR
is less due to nonflushing of debris, which is trapped in the
spark gap and not carried away quickly by the dielectric
fluid.
For the experimental data, ANN is trained with different
nodes in the hidden layer. Low value of RMSE results
in increasing model accuracy. Thus two layers and six
hidden neurons per layer are selected in this study. The

Figure 5.—Effects of factors on material removal rate.

 OPTIMIZATION OF MATERIAL REMOVAL RATE
Downloaded by [Dalhousie University] at 00:22 20 August 2013
Figure 6.—Interaction effects of factors on material removal rate.
predicted results by neural network model are comparable
with experimental results. The introduction of tansig transfer
function in the neural network makes the model adaptive
with better prediction for nonlinear responses of MRR. This
ANN model could predict the MRR in a satisfactory manner.
Choice of important factors within the manufacturing
process is very important because these factors determine
performance especially in case of -EDM. The results
indicate that ANN model can be successfully applied to
predict the machining response.
Combining the above ANN–GA approach, analysis was
carried out to select optimum process parameters for
-EDM of aluminum. Optimization results as in Table
5 were compared with the optimum process conditions
recommended through experimental results for the same
work piece and electrode combinations. The results are valid
for the range of parameters considered in this analysis.
Conclusions
In this study the MRR in the -EDM process
was predicted by feed-forward neural network with
back-propagation algorithm for the pertinent machining
parameters. Extensive simulations were carried out, and the
conclusions are as follows:
1. Optimum neural network with 4-6-6-1 was found to give
reasonably good prediction accuracy for MMR;
2. The developed neural network appropriately trained gave
an average prediction error of 0.8312% for training and
3.94% while testing. The developed models are in close
agreement when experimental results, and the predicted
values are compared;
3. The back-propagation network data along with the
GA that can successfully synthesize optimum input
conditions to maximize the MRR are 124.3 V, 0.2 F,
9 m/s, and 900 rpm;
473
4. The process optimization through ANN modeling and
GA technique was very effective in optimizing the
performance of the -EDM process.
References
1. Kurnia, W.; Tan, P.C.; Yeo, S.H.; Wong, M. Analytical
approximation of the erosion rate and electrode wear in micro
electrical discharge machining. Journal of Micro Mechanics and
Microengineering 2008, 18, 5011–5019.
2. Katz, Z.; Tibbles, C.J. Analysis of micro-scale EDM process.
International Journal of Advanced Manufacturing Technology
2005, 25, 923–928.
3. Izquierdo, B.; Sanchez, J.A.; Plaza, S.; Pombo, I.; Ortega, N.A.
Numerical model of the EDM process considering the effect of
multiple discharges. International Journal of Machine Tools and
Manufacture 2009, 49, 220–229.
4. Salah, N.B.; Ghanem, F.; Atig, K.B. Thermal and mechanical
numerical modeling of electric discharge machining process.
Communications in Numerical Methods in Engineering 2008,
24(12), 2021–2043.
5. Mamalis, A.G.; Vosniakos, G.C.; Vaxevanidis, N.M.; Prohaszka,
J. Macroscopic and microscopic phenomena of electro discharge
machined steel surfaces: An experimental investigation. Journal
of Mechanical Working Technology 1987, 15, 335–356.
6. Duibitonto, D.D.; Eubank, P.T.; Patel, M.R.; Barrufet, M.A.
Theoretical model of electrical discharge machining process. I, A
simple cathode erosion model. Journal of Applied Physics 1989,
66, 4095–4103.
7. Singh, A.; Ghosh, A. A Thermo electric model of material
removal during electric discharge machining. Journal Materials
Processing Technology 1989, 39, 669–682.
8. Dimla, D.E. Jr.; Lister, P.M.; Leighton, N.J. Neural network
solutions to the tool condition- monitoring problem in metal
cutting—A critical review of methods. International Journal of
Machine Tools and Manufacture 1997, 37, 1219–1241.
9. Dini, G. Literature database on applications of artificial
intelligence methods in manufacturing engineering. Annals of the
CIRP 1997, 46, 681–690.
 474
10. De Silva, A.K.M.; McGeough, J.A. Computer applications
in unconventional machining. Journal Materials Processing
Technology 2000, 107, 276–282.
11. Tsai, K.M.; Wang, P.J. Semi-empirical models of surface
finish on electrical discharge machining. International Journal of
Machine Tools and Manufacture 2001, 41, 1455–1477.
12. Tsai, K.M.; Wang, P.J. Comparisons of neural network models
on material removal rate in electrical discharge machining.
Journal of Materials Processing Technology 2001, 117,
111–124.
13. Wang, K.; Gelgele, H.L.; Wang, Y.; Yuan, Q.; Fang, M. A hybrid
intelligent method for modeling the EDM process. International
Journal of Machine Tools and Manufacture 2003, 43, 995–999.
14. Ho, K.H.; Newman, S.T. State of art electrical discharge
machining. International Journal of Machine Tools and
Manufacture 2003, 43, 1287–1300.
15. Ghoreishi, M.; Tabari, C. Investigation of the effect voltage
excitation of pre-ignition spark pulse on the electro-discharge
machining (EDM) process. Materials and Manufacturing
Processes 2007, 22, 833–841.
Downloaded by [Dalhousie University] at 00:22 20 August 2013
16. Perez, R.; Rojas, H.; Walder, G.; Flukigar, R. Theoretical
modeling of energy balance in electro erosion. Journal of
Materials Processing Technology 2004, 149, 198–203.
17. Petropoulos, G.; Vaxevanidis, N.M.; Pandazaras, C. Modeling
of surface finish in electro discharge machining based upon
statistical multi parameter analysis. Journal of Materials
Processing Technology 2004, 155, 1247–1251.
18. Norliana, M.A.; Solomon, D.G.; Bahari, M.F. A review on
current research trends in Electrical Discharge Machining (EDM).
International Journal of Machine Tools and Manufacture 2007,
47, 1214–1228.
19. Panda, D.K.; Bhoi, R.K. Artificial neural network prediction of
material removal rate in electro discharge machining. Materials
and Manufacturing Processes 2005, 20, 645–672.
20. Gadalla, A.M.; Tsai, W. Machining of WC-Co composites.
Materials and Manufacturing Processes 1989, 4, 411–423.
21. Cheng, Y.M.; Eubank, P.T.; Gadalla, A.M. Electrical discharge
machining of ZrB2-based ceramics. Materials and Manufacturing
Processes 1996, 11, 565–574.
22. Guu, Y.H.; Hocheng, H. Effects of workpiece rotation on
machinability during electrical discharge machining. Journal of
Materials and Production Technology 2001, 16, 463–483.
23. Weng, F.T.; Her, M.G. Study of the batch production of micro
parts using the EDM process. The International Journal of
Advanced Manufacturing Technology 2001, 19, 266–270.
24. Yuan, S.; Hung, N.P.; Ngoi, B.K.A.; Ali, M.Y. Development of
micro replication processes–Microinjection molding. Materials
and Manufacturing Processes 2003, 18, 731–751.
25. Guu, Y.H.; Chou, C.Y.; Chiou, S.T. Study of the effect of
machining characteristics in electrical discharge machining of
Fe–Mn–Al alloy. Materials and Manufacturing Processes 2005,
20, 905–916.
26. Lin, Y.-C.; Chen, Y.-F.; Lin, C.-T.; Tzeng, H.-J. Electrical
Discharge Machining (EDM) characteristics associated with
electrical discharge energy on machining of cemented tungsten
carbide. Materials and Manufacturing Processes 2008, 23,
391–399.
27. Ali, M.Y.; Ammar, S.M. Experimental study of conventional
WEDM for microfabrication. Materials and Manufacturing
Processes 2008, 23, 641–645.
K. P. SOMASHEKHAR ET AL.
28. Jose, M.; Suresh Kumar, V.B.; Somashekhar, K.P. Investigation
into influence of process parameters on micro wire electric
discharge machining. Proceedings of COPEN-2007, India,
December 5–7, 2007; 287–294.
29. Mathew, J.; Somashekhar, K.P.; Sooraj, V.S.; Nuvvula, S.;
Ramachandran, N. Effect of work material and machining
conditions on the accuracy and quality of micro holes.
International Journal of Abrasive Technology 2009, 2,
279–298.
30. Somashekhar, K.P.; Jose, M. Fabrication of microelectrodes
for micro EDM operation using micro WEDG, Proceedings
AIMTDR, IITM, Madras, India, December 15–17, 2008;
639–644.
31. Somashekhar, K.P.; Subba Rao, N.; Jose, M. Effect of discharge
conditions on the performance of micro electric discharge
machining: Proceedings of AIMTDR, IITM, Madras, India,
December 15–17, 2008; 615–620.
32. Somashekhar, K.P.; Ramachandran, N.; Jose, M. Modeling and
optimization of process parameters in micro Wire EDM by
Genetic Algorithm. Advanced Materials Research 2009, 76–78,
566–570.
33. Puertas, I.; Luis, C.J. A study of optimization of machining
parameters for electrical discharge machining of Boron Carbide.
Materials and Manufacturing Processes 2004, 19, 1041–1070.
34. Assarzadeh, S.; Ghoreishi, M. Neural-network-based modeling
and optimization of the electro-discharge machining process.
International Journal of Advanced Manufacturing Technology
2008, 39, 488–500.
35. Seung, H.Y.; Srinivas, J.; Sekar, M.; Lee, D.-M.; Sree, B.
Optimization of electric discharge machining using simulated
annealing. Journal of Materials Processing Technology 2008,
209, 4471–4475.
36. Simon, H. Neural Networks: A Comprehensive Foundation; New
Jersey: Pearson Prentice Hall, 2006.
37. Zurada, J.M. Introduction to Artificial Neural Systems; West
Publishing Company: St. Paul, MN, 1994.
38. Fausset, L.V. Fundamentals of Neural Networks: Architecture,
Algorithms and Applications; New Jersey: Prentice Hall, 1994.
39. Deb, K. Optimization for Engineering Designs: Algorithms and
Examples; New Jersey: Prentice Hall, 1995.
40. Deb, K. Multi-Objective Optimization by Evolutionary
Algorithms; Chichester: John Wiley, 2001.
41. Cheng, G.R. Genetic Algorithm and Engineering Design; New
York: John Wiley, 1997.
42. Pettersson, F.; Chakraborti, N.; Saxén, H. A genetic algorithm
based multi-objective neural net applied to noisy blast furnace
data. Applied Soft Computing 2007, 7, 387–397.
43. Helle, M.; Pettersson, F.; Chakraborti, N.; Saxén, H. Modelling
noisy blast furnace data using genetic algorithms and neural
networks. Steel Research International 2006, 77, 75–81.
44. Pettersson, F.; Biswas, A.; Sen, P.K.; Saxen, H.; Chakraborti,
N. Analyzing leaching data for low-grade manganese ore using
neural nets and multiobjective genetic algorithms. Materials and
Manufacturing Processes 2009, 24, 320–230.
45. Saxen, H.; Pettersson, F.; Rajan, K.; Changwon, S.; Chakraborti,
N. Analyzing sparse data for nitride spinels using data mining,
neural networks, and multiobjective genetic algorithms. Materials
and Manufacturing Processes 2009, 24, 2–9.
46. Datta, S.; Pettersson, F.; Ganguly, S.; Saxén, H.; Chakraborti, N.
Identification of factors governing mechanical properties of
 OPTIMIZATION OF MATERIAL REMOVAL RATE
TRIP-aided steel using genetic algorithms and neural networks.
Materials and Manufacturing Processes 2008, 23, 131–138.
47. Sen, M.; Shan, H.S. Optimal selection of machining conditions
in the electrojet drilling process using hybrid NN-DF-GA
approach. Materials and Manufacturing Processes 2006, 21(4),
349–356.
48. Bhattacharya, B.; Dinesh Kumar, G.R.; Akash, A.; Şakir, E.;
Singh, A.; Chakraborti, N. Analyzing Fe–Zn system using
molecular dynamics, evolutionary neural nets and multi-objective
Downloaded by [Dalhousie University] at 00:22 20 August 2013
475
genetic algorithms. Computational Materials Science 2009, 46(4),
821–827.
49. Pettersson, F.; Suh, C.; Saxén, H.; Rajan, K.; Chakraborti, N.
Analyzing sparse data for nitride spinels using data mining,
neural nets, and multi-objective genetic algorithms. Materials and
Manufacturing Processes 2009, 24, 2–9.
50. Demuth, H.; Beale, M.; Hagan, M. Neural network toolbox,
Math. works, Inc.: Natick, MA. 2001. Available online at
http://www.mathworks.com (Accessed 4 September 2009).