Advanced Materials Research Vols 264-265 (2011) pp 985-990 Online: 2011-06-30

© (2011) Trans Tech Publications, Switzerland

doi:10.4028/www.scientific.net/AMR.264-265.985

PARETO OPTIMIZATION OF ELECTRO DISCHARGE MACHINING OF

TITANIUM NITRIDE-ALUMINIUM OXIDE COMPOSITE MATERIAL USING
GENETIC ALGORITHM

Souren Mitra1,a, Soumya Sarkar1,b, Goutam Paul1,c, D.Bhaduri1,d,

Sampad Biswas2,e
1.
Production Engineering Department, Jadavpur university, Kolkata, India.
2.
Central Glass and Ceramic Research Institute,CSIR, Kolkata, India.
email: souern_mitra@sify.com , b soumyasarkar@vsnl.net , c goutamju04@gmail.com,
a
d
debajyotibhaduri@gmail.com e sampad@cgcri.res.in

Keywords: Titanium nitride-aluminium oxide (TiN-Al2O3) composite; MRR; EWR; ROC; Taper
angle, Genetic Algorithm, Pareto optimal search, Multi Objective Optimization.

ABSTRACT: Titanium nitride-aluminium oxide (TiN-Al2O3) is a new generation ceramic

composite material having potential for many industrial applications as it possesses high resistance
to thermal degradation, anti-wear and anti-abrasion properties. In the present research the
characteristic features of EDM process are explored through Taguchi methodology based
experimental studies with various process parametric combinations. Finally the process has been
optimized using Genetic algorithm based Pareto optimization search. From Pareto optimal search
the technology guideline for optimal parameter settings have been selected. The present research
approach is extremely useful for maximizing the productivity while maintaining the geometrical
accuracy within desired limit.

1. INTRODUCTION
Titanium nitride-aluminium oxide (TiN-Al2O3) is a new generation advanced ceramic composite
having high resistance to thermal degradation and can be used for heat shielding. Moreover, as TiN
and Al2O3 are highly wear and abrasion resistant materials [1], this ceramic composite has a good
potential to be used as cutting tool material. High chemical stability, low friction coefficient and
high hardness etc. are the key properties responsible for its application in component of complex
shapes.
Although titanium nitride-aluminium oxide composite has many potential industrial application
areas, conventional machining of such type of advanced ceramic composites is difficult to perform
as they possess some peculiar properties like anisotropy, low thermal conductivity and abrasive
nature of the reinforcing phases [2]. As a result, a full-scale application of these advanced materials
is hindered by high cost of conventional machining [3]. Sarkar et al. [4-5] performed a parametric
optimization and set a technology guideline for optimum parameter settings for wire electro
discharge machining of TiN-Al2O3 composite. However, no guidelines or technology settings are
available in the literature for die-sinking electro discharge machining of this material. Therefore, the
present research exhibits the characteristic features of electro discharge machining of TiN-Al2O3
composite through Taguchi L9 orthogonal array [6] based experimental studies. The process
parameters chosen were pulse-on time, peak current, duty cycle and gap voltage and the measured
responses were material removal rate, electrode wear rate, radial over cut and taper angle. The
optimal parameter settings for the responses were determined with the help of Genetic algorithm
based Pareto optimal search. Optical Microscopic and SEM analysis have also been carried out on
the composite matrix to verify the presence of two distinguishable phases like TiN and Al2O3. The
mechanical and electrical properties of the work material are furnished in Table 1.

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986 Advances in Materials and Processing Technologies II

Table 1 Mechanical Properties of TiN-Al2O3 Work Material

Property Unit Value
TiN content [Mol %] 66
Density [kg.m-3] 4342
Strength (Flexural) 4 points [MPa] 440
Vicker’s Hardness [GPa] 20
Young’ s Modulus [GPa] 270
DC Resistivity [Ω.m] 0.25
Thermal conductivity [W.m-1.K-1] 21±1
Thermal expansion [K-1] 8.78 E-6

2. EXPERIMENTAL SET UP

An ‘Electra’ EMS 5535 R-50 ZNC, series 2000, die sinking EDM machine was used for the
experiments. The dimension of the work material was 20 mm × 5 mm × 1 mm cut out from a
reactive hot pressed billet of TiN-Al2O3 composite. Copper was used as tool material. During
machining, the polarity of the electrode was kept negative and that of the workpiece positive. A
‘Mettler Toledo’ digital weighing machine, type AG285, was used for measuring the weight of the
workpieces and electrodes before and after each machining operation for the purpose of calculating
material removal rate (MRR) and electrode wear rate (EWR). An ‘Olympus’ measuring microscope
of type STM6 was used for measuring the diameters of the drilled holes after the machining
operations for calculating the radial overcut (ROC) and taper angle (α°). SEM micrographs have
been taken by a Scanning Electron Microscope (Jeol, JSM 5800).

3. PLANNING FOR EXPERIMENTATION AND TEST RESULTS

After some initial trial experimental runs, a satisfactory working range for the input parameters
was established. The planning of experiment for the electro discharge machining of TiN-Al2O3
composite was based on Taguchi L9 orthogonal array. A total number of 9 experiments have been
performed. The input factors were pulse-on Time (Ton), peak current (Ip), duty cycle (t) and gap
voltage (Vg). The responses measured were material removal rate (MRR), electrode wear rate
(EWR), radial overcut (ROC) and taper angle of the through holes (α°).
The Taguchi L9 orthogonal array and experimental results are given in Table 2.

Table 2 Taguchi L9 orthogonal array and experimental results

Exp Pulse on Peak Duty Gap Material Electrode Radial Taper
No time(Ton) current cycle voltage removal wear rate overcut angle (α)
[µs] (Ip) (t) (Vg) rate (MRR) (EWR) (ROC) [degree]
[Amp] [%] [volts] [mg/min] [mg/min] [mm]
1 10 1 59 22 0.066 0.073 0.0566 10.33
2 10 2 79 32 0.129 0.032 0.0325 9.34
3 10 3 96 42 0.160 0.024 0.0436 8.47
4 20 1 79 42 0.089 0.007 0.0574 14.35
5 20 2 96 22 0.071 0.123 0.0353 10.63
6 20 3 59 32 0.095 0.017 0.0230 10.19
7 30 1 96 32 0.063 0.008 0.0387 9.01
8 30 2 59 42 0.115 0.009 0.0305 8.79
9 30 3 79 22 0.095 0.033 0.0254 6.79
 Advanced Materials Research Vols. 264-265 987

4. MULTI RESPONSE OPTIMIZATION OF EDM PROCESS PARAMETERS

In fine hole drilling by EDM the prime objective is to maximize the productivity (i.e. MRR)
while maintaining the desired accuracy features (i.e. ROC, taper angle etc). Taguchi based
optimization gives optimization of one parameter at a time i.e. single objective optimization and as
such this method is not directly applicable under this circumstance. In order to achieve this, the
process has been first modelled by means of regression analysis using the experimental data shown
in Table 2. The expressions for MRR, ROC and taper angle are as follows:

MRR= -0.0019 - 0.00139 Ton + 0.022 Ip + 0.000169 t + 0.00221 Vg (1)

ROC= 0.0582 - 0.000635 Ton - 0.0101 Ip + 0.000068 t + 0.000237 Vg (2)
Taper angle= 12.4 - 0.0591 Ton - 1.37 Ip -0.0101 t + 0.0646 Vg (3)

As already stated the main objective is to increase the MRR while maintaining the ROC and taper
angle within a specified limit, it can be formulated as a case of constraint optimization problem and
has been solved using Genetic algorithm based Pareto optimal search.
In the present case the problem has been formulated as follows:
Maximize MRR= f(Ton, Ip, t, Vg) (4)
Subject to ROC[=f(Ton, Ip, t, Vg)]≤ α1
10≤Ton≤30[µs], 1≤Ip≤3[Amp]
59≤t≤96[%], 22≤Vg≤42[Volts]
where α1 is maximum allowable ROC value. The value of α1 should be within the range of
predicted ROC values i.e. within 0.196 mm and 0.037 mm.
Similarly again, the multi objective criteria have been used which is as follows:
Maximize MRR= f(Ton, Ip, t, Vg) (5)
Subject to Taper Angle[=f(Ton, Ip, t, Vg)]≤ α2
10≤Ton≤30[µs], 1≤Ip≤3[Amp]
59≤t≤96[%], 22≤Vg≤42[Volts]
where α2 is maximum allowable taper angle value. The value of α2 should be within the range of
predicted taper angle values.
Pareto optimal solutions mean that it is better than any other output at least with respect to one
process criterion i.e. ROC or MRR and/or taper angle or MRR. If one parameter combination
results in higher in both the process criterion or if it is higher with respect to at least one process
criterion and is equal with respect to other process criterion should never be selected in preference
to the first. The multi objective problem is solved with the help of MATLAB 7.6 software and all
Pareto optimum points are searched out for both the cases. Among all these Pareto optimal points
which are not applicable from practical consideration (e.g. some parameter setting can not be
implemented in the present EDM machine) has been separated and finally 29 set of Pareto optimal
solutions for MRR, ROC and 31 set of Pareto optimal solutions for MRR and taper angle has been
obtained.
0.16 0.16

0.15 0.15
0.14
0.14
MRR(mg/min)

MRR(mg/min)

0.13
0.13
0.12
0.12
0.11
0.11
0.10

0.09 0.10

0.08 0.09
0.018 0.020 0.022 0.024 0.026 0.028 0.030 0.032 0.034 0.036 0.038 7.0 7.5 8.0 8.5 9.0 9.5
Radial Overcut (mm) Taper Angle(Degree)

Fig. 1 Maximized MRR v/s Fig. 2: Maximized MRR v/s

minimized ROC plot minimized taper angle plot
988 Advances in Materials and Processing Technologies II

The set of all Pareto optimal solutions for MRR, ROC and MRR, taper angle are shown in part 1
and part 2 of Table 3 respectively. Table 3 contains the sorted list of all these optimum parametric
combinations in the increasing order of ROC and taper angle respectively.These set of optimal
parameter settings are very useful for manufacturing engineer who can adapt to different optimal
solutions as per customer specification and requirement. For example if ROC is less than or equal to
0.0265, the best parametric combination would be (Sl No 20 of part 1 of Table 3) as follows:
Ton=27µs, Ip=3Amp, t=79%, Vg=42Volts
This will yield the highest possible MRR = 0.1323 mg/min while maintaining the specified ROC
requirement i.e. 0.0265mm. It may be noted that any other parameter setting either results in lower
MRR or fails to achieve the stipulated ROC.
Again consider another example i.e. if taper angle is required to be less than or equal to 8.39º,
the best parametric combination would be (Sl No 17of part 2 of Table 3) as follows:
Ton=23µs, Ip=3Amp, t=93%, Vg=37Volts
This will yield the highest possible MRR = 0.129 mg/min, maintaining the specified taper angle
requirement i.e.8.39º. In Fig. 1 and Fig. 2 plot of all these optimum points is shown. From these plot
it can be observed that the accuracy of the drilled hole decreases as the maximum MRR increases
i.e. with increase of MRR both radial overcut and taper angle increase and thereby deteriorating the
accuracy of hole. In a production environment it is sometimes desirable to limit the ROC as well as
taper angle within a specified limit. Under such circumstances, an optimum parametric combination
should produce the maximum MRR, while maintaining ROC and taper angle within the desired
limit. This may again be considered as a multi-constrained optimization problem. In this case one
needs to find out the optimal solution considering both part 1 and part 2 of Table 3.
For example if the required for ROC is less than or equal to 0.0231 mm and as well as the taper
angle is less than or equal to 8.13 º, then the best parameter setting should be searched out
considering both part 1 and part 2 of Table 3 and it is found that the optimum solution is (Sl No 14
part 1 of Table 3) as follows:
Ton=30µs, Ip=3Amp, t=73%, Vg=38Volts
This will yield the highest possible MRR= 0.119 mg/min and ROC 0.0230 mm and Taper angle
8.13 º.
 Advanced Materials Research Vols. 264-265 989

Table 3: Technology guideline for optimal parameter setting

Part 1. Maximized MRR at minimized ROC Part 2. Maximized MRR at Minimized Taper Angle
Sl. Control Factors Responses Control Factors Responses
No. Taper
Ton Ip T Vg ROC MRR Sl. Ton Ip T Vg Angle MRR
(µs) (Amp) (%) (volts) (mm) (mg/min) No. (µs) (Amp) (%) (volts) (degree) (mg/min)
1 30 3 73 24 0.0196 0.088 1 24 3 93 23 7.45 0.098
2 30 3 73 25 0.0197 0.089 2 24 3 93 24 7.48 0.099
3 30 3 73 26 0.0201 0.093 3 23 3 92 24 7.51 0.100
4 30 3 73 27 0.0203 0.095 4 24 3 92 25 7.57 0.102
5 30 3 73 28 0.0206 0.097 5 24 3 93 26 7.61 0.103
6 30 3 73 29 0.0209 0.100 6 23 3 92 27 7.75 0.107
7 30 3 73 30 0.0210 0.101 7 23 3 92 28 7.76 0.108
8 30 3 73 31 0.0213 0.104 8 24 3 93 29 7.81 0.110
9 30 3 74 32 0.0214 0.105 9 23 3 93 30 7.89 0.113
10 30 3 74 33 0.0218 0.108 10 24 3 93 31 7.93 0.114
11 30 3 73 34 0.0221 0.110 11 22 3 92 30 7.98 0.115
12 30 3 74 36 0.0226 0.115 12 23 3 92 32 8.04 0.118
13 30 3 74 37 0.0229 0.117 13 23 3 92 33 8.13 0.121
14 30 3 73 38 0.0230 0.119 14 24 3 93 35 8.21 0.124
15 30 3 74 40 0.0233 0.123 15 23 3 92 35 8.27 0.126
16 30 3 75 41 0.0237 0.126 16 23 3 92 36 8.34 0.128
17 29 3 78 41 0.0245 0.128 17 23 3 93 37 8.38 0.129
18 28 3 79 42 0.0253 0.130 18 23 3 92 38 8.47 0.132
19 28 3 81 42 0.0256 0.131 19 23 3 92 39 8.53 0.135
20 27 3 79 42 0.0262 0.132 20 21 3 92 39 8.59 0.135
21 25 3 80 42 0.0274 0.135 21 22 3 92 40 8.60 0.136
22 24 3 81 41 0.0281 0.136 22 21 3 92 40 8.72 0.140
23 22 3 81 42 0.0291 0.139 23 20 3 92 40 8.78 0.141
24 20 3 79 41 0.0303 0.141 24 19 3 92 40 8.84 0.142
25 19 3 78 42 0.0312 0.143 25 18 3 92 40 8.88 0.143
26 16 3 81 42 0.0331 0.147 26 17 3 92 40 8.99 0.146
27 15 3 78 42 0.0335 0.148 27 16 3 92 40 9.04 0.147
28 13 3 81 42 0.0352 0.152 28 15 3 92 40 9.09 0.148
29 12 3 82 42 0.0361 0.154 29 14 3 92 40 9.17 0.150
30 13 3 92 41 9.21 0.151
31 12 3 92 41 9.30 0.153

5. OPTICAL & SEM IMAGES OF DRILLED HOLES

Fig. 3 exhibits the optical microscopic view of one of the drilled holes. Fig. 4 & 5 exhibit the
SEM images of one of the drilled hole from top and bottom sides respectively. In Fig. 6, SEM
image of the periphery of the drilled hole (from top) is shown. It has been observed that, at the entry
of the hole, some material is bulged out. This bulging out is not observed at the exit of the hole.
This may be the reason behind the formation of taper holes.

Fig. 3 Optical Microscopic View of Fig. 4 SEM View of Drilled Hole

Drilled Hole (from top)
990 Advances in Materials and Processing Technologies II

Fig. 5 SEM View of Drilled Hole Fig. 6 SEM View of Periphery of

(from bottom) Drilled Hole(from top)

6. CONCLUSIONS

In the present research the experimental results have been optimized using genetic algorithm
based Pareto optimization search. By Pareto optimal search optimal points have been selected for
the technology guideline for optimal parameter settings that are very useful for manufacturing
engineer performing electro discharge machining on TiN-Al2O3 ceramic composite material. The
present research work is extremely useful for maximizing the productivity, at the same time
maintaining the geometrical accuracy within a desired limit. The developed technology setting in
the field of electro discharge machining of TiN-Al2O3 composite will give a valuable and potential
guideline in modern industrial applications for efficient manufacturing of precision jobs.

REFERENCES

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496.
[2] W. S. Lau, T.M.Yue, T. C.Lee, W. B. Lee, Un-conventional machining of composite materials.
Journal of Materials Processing Technology 1995, 48, 199-205.
[3] N. P.Hung, L. J.Yang, K. W. Leong, Electrical discharge machining of cast metal matrix
composites. Journal of Materials Processing Technology 1994, 44, 229-236.
[4] S. Sarkar, S. Mitra, B. Bhattacharyya, Parametric analysis and optimization of wire electrical
discharge machining of γ-titanium aluminide alloy. Journal of Materials Processing
Technology 2005, 149, 347-352.
[5] S. Sarkar, M. Sekh, S. Mitra, B. Bhattacharyya, Modeling and optimization of wire
electrical dischargemachining of γ-TiAl in trim cutting operation, Journal of
Materials Processing Technology 2008, 205, 376-387.
[6] T. P. Bagchi, Taguchi Methods Explained: Practical Steps to Robust Design. Press: Prentice-
Hall of India Pvt Ltd, New Delhi, 1993.
Advances in Materials and Processing Technologies II
10.4028/www.scientific.net/AMR.264-265

Pareto Optimization of Electro Discharge Machining of Titanium Nitride-Aluminium Oxide Composite

Material Using Genetic Algorithm
10.4028/www.scientific.net/AMR.264-265.985