Applied Soft Computing 70 (2018) 665–679

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Applied Soft Computing

journal homepage: www.elsevier.com/locate/asoc

Application of GRNN and multivariate hybrid approach to predict and

optimize WEDM responses for Ni-Ti shape memory alloy
Himadri Majumder, Kalipada Maity ∗
Department of Mechanical Engineering, National Institute of Technology, Rourkela 769008, Odisha, India

a r t i c l e i n f o a b s t r a c t

Article history: The current investigation aims at highlighting the application potential of a smart approximation tool,
Received 31 August 2017 which is general regression neural network (GRNN) during machining of nickel-titanium (Ni-Ti) shape
Received in revised form 19 June 2018 memory alloy using WEDM. A series of experiments were accomplished based on Taguchi’s orthogonal
Accepted 20 June 2018
layout design. Pulse on time, discharge current, wire tension, wire speed and flushing pressure were
Available online 23 June 2018
considered as five distinct WEDM parameters, whereas arithmetic mean roughness, maximum peak to
valley height, root mean square roughness, and micro-hardness were selected as the major responses
Keywords:
to be investigated. The aforementioned WEDM responses were predicted with the help of the projected
Fuzzy
Optimization GRNN model and compared with the experimental results. The investigation was further extended to
Shape memory alloy ascertain the optimum combination of input parameters using a hybrid approach. This was done by
VIKOR combining VIKOR method with the Fuzzy logic system. The prediction error of the GRNN model was
WEDM noted as ±5% within the studied range of machining parameters. Finally, the adequacy of the multivariate
VIKOR-Fuzzy approach was verified by performing confirmation test which exhibited improvement in
WEDM responses.
© 2018 Elsevier B.V. All rights reserved.

1. Introduction thermo-electric energy to precise machine nearly any conductive

Shape memory alloy (SMA) belongs to a unique class of mate-
rials, which can retain or memorize their previous form when
subjected to certain thermo-mechanical or magnetic load [1–3].
Many SMAs also exhibit pseudo-elastic or super-elastic behav-
ior, which allows them to return their original shape after large
deformation [4]. Superior fatigue performance, excellent biocom-
patibility, high elasticity, and high corrosion resistance makes
nickel-titanium (Ni-Ti) SMA imperative choice in different fields
like microengineering, biomedical, aerospace, robotics, automo-
tive, civil structures and magician tricks, etc. [5–9]. On the contrary,
the high toughness, ductility and chemical reactivity of Ni-Ti SMA
adversely affect its machinability using conventional machining
operation [10–12]. Wire electrical discharge machining (WEDM),
which is not dependent on the mechanical assets of the work-
piece, is the best-suited procedure for machining of “difficult to
machine” materials which are problematic to process by conven-
tional machining processes.
WEDM is one of the most precise, flexible, swiftly developed
and an essential non-conventional machining process that uses
∗ Corresponding author.
E-mail addresses: himu.nita@gmail.com (H. Majumder), kpmaity@nitrkl.ac.in
(K. Maity).
material, including difficult to cut materials like SMAs, ceram-
ics, tool steel, composites, hardfacing material, etc. [13–18]. In
the recent past, the WEDM operation has persisted as a practi-
cal and competitive machining alternative fulfilling the growing
demand in manufacturing industry in the growing economic pres-
sure. As there is no direct contact between the workpiece and wire
electrode during WEDM operation, the problems related to the con-
ventional machining processes like stress, vibration and chatter
are significantly eliminated. In this operation, a series of tiny elec-
tric discharges are created in between the workpiece material and
wire electrode which removes a little segment of material by melt-
ing and/or vaporization. At the same time, using upper and lower
nozzles, machining zone is regularly flushed with dielectric fluid
which removes the debris formed due to electro-erosion process.
These continuous sparkings and dielectric flushing form a hard,
brittle and uneven machined surface which makes surface rough-
ness and micro-hardness as an important machining outcome in
WEDM operation [19]. Thus, to maintain the quality of machined
surfaces, low surface roughness, and high micro-hardness is highly
recommended. However, it is critical to set the appropriate input
conditions in the view of appropriate surface roughness and micro-
hardness of the product due to an excessive number of non-linear
machining factors. To overcome this difficulty, several eminent
practitioners have proposed different multivariate approaches.

https://doi.org/10.1016/j.asoc.2018.06.026
1568-4946/© 2018 Elsevier B.V. All rights reserved.
666 H. Majumder, K. Maity / Applied Soft Computing 70 (2018) 665–679
Fig. 1. EDS analysis of Ni-Ti shape memory alloy.
Recently, the Fuzzy logic based multivariate approach has
turned out to be exceptionally popular to find out the opti-
mum machining parametric setting. Puhan et al. [20] used Fuzzy
inference system coupled with principal component analysis
(PCA) in association with the Taguchi method to optimize EDM
input parameters. Lin et al. [21] introduced grey-Fuzzy reasoning
grade and analysis of variance (ANOVA) to optimize EDM pro-
cess parameters simultaneously. Bhaumik et al. [22] integrated
desirability function with Fuzzy-logic to optimize powder mixed
EDM responses. Taguchi and Fuzzy-TOPSIS approaches were intro-
duced to optimize pulse duration, peak current, flushing pressure
and dielectric level for green EDM operation [23]. Maher et al.
[24] applied adaptive neuro-Fuzzy inference system (ANFIS) in
WEDM operation to decide the significant parameters and predict
WEDM responses. Gul et al. [25] in their review article showed a
broad application of VIKOR and its extension in a Fuzzy environ-
ment in “Design, mechanical engineering and manufacturing” field.
Researchers also displayed the effectiveness of the VIKOR-Fuzzy
method in several managerial as well as civil applications [26–29].
With the traditional techniques, it is tough to predict WEDM
responses due to the complex and uncertain mechanism. Some
advanced soft computing methods viz. artificial neural network
(ANN), general regression neural network (GRNN), etc. are note-
worthy to predict these responses with colossal success in view of
their phenomenal ability to learn from experimental data and to
represent interaction and nonlinear relationship with input vari-
ables [30–32]. In 1991, Donald Specht introduced a probabilistic
neural network method GRNN [33], a learning algorithm used for
function approximation. GRNN is preferred among numerous soft
computing techniques due to its ability to assess continuous vari-
ables with fast training. Similarly, it can evaluate a function directly
from training data without repetition of the training course and
can estimated any random function among input and responses.
Few researchers employed GRNN efficiently for non-conventional
machining problems [34,35], the electrical field [36], the medical
field [37], the image processing field [38] and in different other
areas [39–42].
To meet the global competitiveness in precision manufacturing,
selection of the best parametric setting for preferred responses,
prediction and continuous monitoring of processes are substan-
tially necessary. On the other hand, the availability of various
choices and contradictory nature of different responses, makes it
hard to choose the best or an optimal parametric combination.
From the past studies, it is apparent that few efforts have been
conveyed to acquire the aforesaid objectives. But very less consid-
eration has been paid to select the optimum machining condition
in WEDM for contradictory responses like surface roughness (Ra,
Rq and Rz) and micro-hardness (MH) together for Ni-Ti SMA. Addi-
tionally, the literature is also lacking in accessing the multivariate
hybrid approach, i.e. VIKOR-Fuzzy in WEDM operation. In addition
to that, a little consideration has been given to predict WEDM out-
puts using different soft-computing techniques. So there is a serious
demand to develop an appropriate model which will strengthen the
machining performance of WEDM as well as can predict machin-
ing responses with very less error. The originality of this research
lies in, to fill these research crevices. Therefore, in this research,
the experiments were concentrated on developing a prediction
and optimization model by varying the key machining parameters
viz. pulse-on time, discharge current, wire tension, wire speed and
flushing pressure during WEDM of Ni-Ti SMA. A productive GRNN
model has been projected to predict WEDM outputs such as Ra, Rq,
Rz and MH. The work has been further extended by introducing a
hybrid multivariate approach, namely, VIKOR-Fuzzy, to decide an
ideal machining parametric setting. ANOVA test has been carried
out to determine the significant parameter affecting the responses.
The adequacy and the effectiveness of the proposed multivariate
hybrid model has been verified by executing the residual analysis
and confirmation test respectively. The results of the work also has
been compared with others in the state of the art.
2. Materials
Ni-Ti shape memory alloys are rapidly becoming the most
demanding SMA. In the last few years, equiatomic Ni and Ti SMA
have become the material of choice in medical fields as dental
implants and self-expanding stents, etc. as well as filters, bas-
kets and several other devices for interventional procedures [43].
Energy dispersive spectroscopy (EDS) analysis shows the chemi-
cal composition of Ni-Ti SMA (Fig. 1). In this experimental study
1.3 mm thick Ni-Ti plate having length 400 mm and width 30 mm
has been taken as workpiece material.
3. Experimental details
3.1. Experimental layout
In the present study, design of experiment (DOE) Taguchi’s L27
orthogonal array (OA) was used and each setting was repeated
twice for better accuracy. This DOE consisted of five controlled
parameters, and each input parameter was examined at three lev-
els (high, medium and low) to inspect the nonlinear effect of the
parameters. In this finishing operation, the input parameter range
was selected by available machine specification, trial and error pro-
cess to avoid the wire breakage. Taguchi’s L27 orthogonal array is
considered to attain greater machining productivity with desirable
accuracy [44,45].
 H. Majumder, K. Maity / Applied Soft Computing 70 (2018) 665–679 667

Fig. 2. Experimental layout.

Table 1 and then with the help of the test load the hardness value was cal-
Input parameters and associate levels.
culated. To increase the assessment precision, MH was measured
Input Parameter Unit Denotation Level at five diverse locations and for final evaluation the average value
was taken. The experimental layout is shown in Fig. 2.
High Medium Low

Pulse on time ␮s TON 14 12 10

Discharge current A I 12 10 8
Wire speed mm/s WS 240 195 150 4. Methodology adopted
Wire tension N WT 14 12 10
Flushing pressure Bar FP 10 8 6 In this segment, a proposed methodology for prediction of
Wire: Brass; Composition: 60–63% Cu and balance Zn; Diameter: 0.3 mm. WEDM responses and optimization of WEDM machining param-
Di-electric: De-ionized water having conductivity 0.055 ␮S. eters are discussed (see Fig. 4).

3.2. Experimental setup

A set of experiments was executed on CNC WEDM (model:
AGIECUT PROGRESS-2). Five significant input parameters viz.
pulse-on time (TON ), discharge current (I), wire tension (WT), wire
speed (WS) and flushing pressure (FP) were considered for machin-
ing purpose. Brass wire having diameter 0.30 mm was used as wire
electrode, the de-ionized water was utilized as di-electric medium
for this investigation (see Table 1).
3.3. Response data collection
According to DOE, for each setting, along the workpiece 6 mm
length was cut. Work pieces were machined in a single loading
which would decrease the loading and unloading period of the test
specimens on the machine. The value of different surface rough-
ness (SR) factors, viz. arithmetic mean roughness (Ra), maximum
peak-to-valley height (Rz) and root mean square roughness (Rq)
were detected using 3D PROFILOMETER (maker: Taylor Hobson).
Measurement for Ra, Rq and Rz were executed at 5 diverse places
on the machined surface and the mean value was considered to
augment the accurateness of the measurement. Micro-hardness
(MH) of all the machined surfaces was measured utilizing micro-
hardness tester (maker: Leco). Micro-hardness test is a procedure
to find out the workpiece hardness on a microscopic scale. A spe-
cific diamond indenter was impressed for 10 s into the workpiece at
300 gf load. Microscopically the impression length was measured
4.1. General regression neural network (GRNN) model
The main aim behind the use of GRNN is to control and pre-
dict inadequate data using a one-pass learning algorithm with an
overly parallel structure. To predict the responses in GRNN, the
data set needs to be preprocessed which involves smoothing. GRNN
includes four layers viz. input, pattern, regression and output layer.
Input layer demonstrates all the input data or information pro-
vided in the structure. In the pattern layer, every input data were
performed all together. Therefore, the total number of experiment
involved for the training will be totally equal to the total number
of neurons. Regression layer contains an extra neuron which calcu-
lates the probability density function whereas the output layer is
engaged to evaluate the output. For GRNN model, very less train-
ing datasets are required compared to other ANN models [46]. An
example of GRNN architecture having “a” number of input param-
eters, “n” number of experiments and “b” number of responses is
shown in Fig. 3.
In the current study, with the help of experimental data, the
proposed GRNN model was set up where input parameter I, TON ,
WT, WS and FP were considered as input layer whereas WEDM
responses Ra, Rq, Rz and MH were considered as the output layer.
The simulation was executed using MATLAB R2015b software
codes with the help of HP desktop (configuration: Intel Core i7-4770
3.4 GHz CPU and 4 GB RAM). GRNN predicted the WEDM responses
for a different combination of TON , I, WT, WS and FP.
668 H. Majumder, K. Maity / Applied Soft Computing 70 (2018) 665–679

Fig. 3. Architecture of GRNN model.

Fig. 4. Schematic illustration of proposed methodology.

4.2. Multivariate VIKOR-Fuzzy approach which is closer to the ideal solution among the conflicting criteria
by using a ranking system [25]. Normalization using VIKOR method
4.2.1. Data normalization using VIKOR (Vise Kriterijumska involves the following steps [48]:
Optimizacija Kompromisno Resenje) 1st Step: It is to identify the problem and objectives.
Aiming at optimizing WEDM process parameters, output 2nd Step: In the second step, several results achieved through the
parameters cannot be compared in their original sequence as they experiments were converted into a decision matrix form.
have dissimilar units. As WEDM responses are different in units
⎡ ⎤
as well as in magnitude, normalization of response data is essen- x11 x12 . x1j x1n
tial for the simultaneous optimization of the process parameters. ⎢ ⎥
⎢ x21 x22 . x2j x2n⎥
To ensure dimensionless units of variable data, VIKOR was intro- ⎢ ⎥
duced to normalize WEDM responses. In 1980 Serafim Opricovic ⎢ . . ⎥
X=⎢ ⎥
. . .
⎢x ⎥ (1)
developed VIKOR method to solve decision problems having con-
⎢ i1 xi2 . xij . ⎥
flicting criteria and got international recognition [47]. VIKOR is a ⎢ ⎥
Serbian name pronounced as Vise Kriterijumska Optimizacija Kom- ⎣ . . . . . ⎦
promisno Resenje. It is practiced to acquire a compromise solution xm1 xm2 xmj xmn
 H. Majumder, K. Maity / Applied Soft Computing 70 (2018) 665–679 669

where, the row signifies the alternatives (i = 1, 2, 3,. . ...m) and the
column indicated the corresponding measured outcomes for each
alternative. (j = 1, 2, 3, . . . n).
3rd Step: In the last step, normalization of the performance mea-
sure was prepared to make it dimensionless quantity using Eq.
(2).
 x
xij =  ij (2)

m 2

x
ij
i=1


where, xij indicated the normalized value.
Fig. 5. Variation in average arithmetic mean roughness (Ra).
4.2.2. Hybrid VIKOR-Fuzzy approach
The Fuzzy model is a computing framework on the basis of
Fuzzy set theory, Fuzzy reasoning and Fuzzy if-then rules [49]. It
is a numerical hypothesis of inexact reasoning that permits mod-
eling of the reasoning process which is exceptionally reasonable
in characterizing the connection between system inputs and pre-
ferred outputs by enabling the use of human heuristic knowledge
[50,51]. The Fuzzy interface system comprises of a membership
function, Fuzzifier, inference engine, Fuzzy rule base and defuzzi-
fier [52]. Fuzzy logic presents numerous advantages in real time
applications like fast processing time, lesser complication, easy to
comprehend and interpret, well adapted for uncertain data and can
provide a quantitative comparison.
After normalization of the conflicting performance measure, the
Fuzzy logic system (FLS) and the Fuzzy set were developed.
Fig. 6. Variation in average root mean square roughness (Rq).
4.2.2.1. Membership function (MF). In FLS, at first, every experi-
mental output or input data was converted to several degrees of
membership function (MF). Different types of membership func-
tions like triangular, sigmoid, trapezoidal and gaussian, etc. are
used for Fuzzy analysis [22]. It transforms the crisp input values
into appropriate linguistic values. Triangular MF was chosen for
the investigation and distributed into identical intervals, usually
ranging from 0–1. Simultaneously, the output, i.e., VIKOR-Fuzzy
reasoning grade (VFRG) is fuzzified using different MF in identical
intervals.

4.2.2.2. Fuzzy rules. The relationship between the input and the
output in the Fuzzy model is known as Fuzzy rules which is rep-
resented by a set of the linguistic testimonial [53]. It is applied
between the input and output depending on “higher the better”
characteristic in the form of “if-then” control rule. Fig. 7. Variation in average maximum peak to valley height (Rz).

4.2.2.3. Defuzzifier. Using the center of gravity defuzzification

method, the crisp value of VFRG was obtained. To implement the
Fuzzy logic, the MATLAB Fuzzy logic toolbox was used. Defuzzifier
converted the inference Fuzzy results into crisp values [54].
After getting the crisp value of VFRG, main effect plot of
VFRG was drawn using MiniTab statistical software. The optimum
input parameter combination was then assessed using “higher-the-
better” characteristic. Confirmation test was executed following
the ideal parameter combination to examine the model accuracy
of WEDM for Ni-Ti SMA.

5. Results and discussions

WEDM performance characteristics Ra, Rq, Rz and MH were esti- Fig. 8. Variation in average micro-hardness (MH).
mated using GRNN. The outcomes of the proposed models were
compared with experimental values to determine the adequacy of
the proposed model. After prediction and validation of the WEDM
responses, optimum combination of the machining parameters was lower surface roughness and higher micro-hardness. The experi-
determined using hybrid multivariate approach VIKOR-Fuzzy for mental outcome is shown in Figs. 5–8.
670 H. Majumder, K. Maity / Applied Soft Computing 70 (2018) 665–679

5.1. GRNN prediction of WEDM responses

In this GRNN model, 54 experimental data sets were adopted

for training, validation and testing purposes. Among them, 60%
datasets were used to train the network, 20% datasets were used to
validate the model and for testing purpose remaining 20% datasets
were used.
m 
2
∧ n=1
Y n exp −Dn ⁄2 2
Y (X) = m  (3)
2
n=1
exp −Dn ⁄2 2

where, (Xn , Yn )= Sample of (X, Y); Dn2 = Scalar function;  2 = Square

of the Gaussian RBF kernel bandwidth [33]; m = Number of data Fig. 9. Cross-validation curve for proposed GRNN model.
sets;

Di2 = (X − Xn )T (X − Xn ) (4)

The implementation of GRNN model has been described as fol-

lows:
1st Step: At the beginning, the complete 54 experimental
datasets was initialized. Among all the datasets, 34 datasets were
used to train the model, 10 datasets were used for validation
and remaining 10 datasets were utilized for testing the predic-
tive model. All the datasets were chosen randomly to follow the
uniformity.
2nd Step: Cross-validation technique was utilized to achieve the
smoothening parameter. For nominal cross-validation error, the
optimum adaptive parameter (␴2 ) was calculated using the grid
search method.
3rd Step: Scalar function (Di 2 ) for each experimental settings Fig. 10. Relationship among experimental values and GRNN predicted values for
(i = 1–54) were obtained in the next step using Eq. (4). Ra.
4th Step: Coefficient was found by substituting Di 2 and ␴ in Eq.
(3).
5th Step: The exponential term was multiplied by the corre-
sponding real output value, Yi in the pattern layer.
6th Step: An additional neuron was utilized in the regression
layer to estimate output probability density function.
7th Step: Within the experiential space, a weighted average of
the GRNN output was predicted.
8th Step: The efficiency of the suggested model was checked by
validation and testing approach using the remaining 40% datasets.

5.1.1. Cross-validation curve

Kernel width (␴) is the only adaptive criterion in GRNN. So, a
smaller value of ␴ provides over fitting of the data and the higher
value of ␴ provides over smoothening. Thus, the smoothening
parameter value is very much crucial for GRNN prediction accu- Fig. 11. Relationship among experimental values and GRNN predicted values for
racy and the generalization ability [55]. To determine the optimum Rq.
kernel width value, the grid search method was used. For the exe-
cution of cross-validation, kernel width for obtaining “N” values
was calculated using the Eq. 5. The cross validation curve for the
kernel bandwidth search shows optimum adaptive parameter (␴2 )
value as 3.64 (see Fig. 9).

 = low + (v − 1) low − high ⁄R (5)

where, v = 1, 2, 3, 4, ..........n;
high = 10;
low = 1;
R = 10;
Fig. 10 shows the graphical representation of experimentally
measured versus GRNN predicted Ra values and a maximum of
−4.80% error was found. A maximum of 4.60% error was observed
from the comparison graph between experimentally measured
versus GRNN predicted Rq values (see Fig. 11). The interrela-
Fig. 12. Relationship among experimental values and GRNN predicted values for
tionship between experimented and GRNN predicted Rz values Rz.
is shown in Fig. 12 and −4.92% maximum error was found. The
 H. Majumder, K. Maity / Applied Soft Computing 70 (2018) 665–679
Fig. 13. Relationship among experimental values and GRNN predicted values for
MH.
relation between experimented and GRNN predicted MH values
is shown in Fig. 13, which shows a maximum of 4.97% error.
Refers to Figs. 10–13, it can be obvious that a linear approximation
is detected between the experimental data and GRNN predicted
values. This shows that GRNN can precisely predict the WEDM
responses with a minimal error.
At the time of GRNN training, a maximum −4.98% error and a
minimum −0.01% error was noticed. The graphical illustration of
the error percentage in trainee datasets is demonstrated in Fig. 14.
After completion of training, the established GRNN model were
validated and tested and then compared with the investigational
values. During GRNN validation, the established percentage error
graph is illustrated in Fig. 15 which shows a maximum error of
−4.83% and a minimum error of 0.33%. Fig. 16 shown the error
percentage diagram throughout GRNN testing with a maximum
Fig. 14. Graphical representation of percentage error in GRNN trainee data.
Fig. 15. Graphical representation of percentage error in GRNN validation data.
671
−4.81% error and a minimum −0.06% error. From the graphical
demonstration it is apparent that the projected GRNN model is in
very good understanding with experimentally measured data and
predicted GRNN values. The results from training, validation and
testing indicate that the projected GRNN model can be executed to
predict or study WEDM outputs within ±5% error.
5.2. Optimization of WEDM process parameters using
multivariate approach VIKOR-Fuzzy
WEDM responses are contradictory with each other, i.e. the
characteristics of Ra, Rq and Rz are preferred as smaller is better
criterion and MH is preferred as higher the better criterion. A mul-
tivariate hybrid approach, VIKOR (Vise Kriterijumska Optimizacija
Kompromisno Resenje) combined with the Fuzzy logic was intro-
duced to ascertain the optimum input parameter combination for
preferred WEDM responses (see Fig. 17).
Optimization of input parameters using multivariate approach
VIKOR-Fuzzy involves the following steps:
1st Step: Initializing the decision matrix.
2nd Step: In the next step, WEDM responses were converted into
normalized dimensionless numbers using VIKOR (see Fig. 18). Ra,
Rq, Rz and MH were normalized using Eq. (2).
3rd Step: After normalizing using VIKOR, the Fuzzy-logic system
was developed.
A Mamdani type Fuzzy interface system was developed using
MATLAB toolbox (see Fig. 19). WEDM responses viz. Ra, Rq, Rz and
MH were used as input in this Fuzzy model and were kept in 3
levels known as Fuzzy subset namely low, medium and high in
equal intervals. Model output known as VIKOR-Fuzzy reasoning
grade (VFRG) is allotted to nine levels or Fuzzy subsets known as
extremely small, very very small, very small, small, medium, large,
672 H. Majumder, K. Maity / Applied Soft Computing 70 (2018) 665–679

Fig. 16. Graphical representation of percentage error in GRNN testing data.

Fig. 17. Flow chart for multivariate VIKOR-Fuzzy approach.

Fig. 18. Variation in normalized values of machining responses (Ra, Rq, Rz and MH).

very large, very very large and extremely large in equal intervals
(see Fig. 20).
4th Step: Consequently, following “higher the better” criterion,
using “if-then” Fuzzy rules, the relationship among the input and
output parameters have been created. In Fuzzy rules editor, total
81 Fuzzy rules (see Table 2) were developed based on experience
and expertise on control engineering [56].
5th Step: In FLS, the fuzzifier used MFs to fuzzify the input values
(normalization values calculated using VIKOR). In a Fuzzy infer-
ence engine, the defuzzifier transforms the Fuzzy linguistic value
 H. Majumder, K. Maity / Applied Soft Computing 70 (2018) 665–679 673

Table 2
Developed Fuzzy rules.

Rule IF THEN
no.
Ra Rq Rz ‘MH VFRG
condition condition condition

1 Low and Low and Low and Low Very High

2 Low and Low and Low and Medium Very Very High
3 Low and Low and Low and High Extremely High
4 Low and Low and Medium and Low High
5 Low and Low and Medium and Medium Very High
6 Low and Low and Medium and High Very Very High
7 Low and Low and High and Low Medium
8 Low and Low and High and Medium High
9 Low and Low and High and High Very High
10 Low and Medium and Low and Low High
11 Low and Medium and Low and Medium Very High
12 Low and Medium and Low and High Very Very High
13 Low and Medium and Medium and Low Small
14 Low and Medium and Medium and Medium Medium
15 Low and Medium and Medium and High High
16 Low and Medium and High and Low Very Small
17 Low and Medium and High and Medium Small
18 Low and Medium and High and High Medium
19 Low and High and Low and Low Medium
20 Low and High and Low and Medium High
21 Low and High and Low and High Very High
22 Low and High and Medium and Low Very Small
23 Low and High and Medium and Medium Small
24 Low and High and Medium and High Medium
25 Low and High and High and Low Very Very Small
26 Low and High and High and Medium Very Small
27 Low and High and High and High Small
28 Medium and Low and Low and Low High
29 Medium and Low and Low and Medium Very High
30 Medium and Low and Low and High Very Very High
31 Medium and Low and Medium and Low Small
32 Medium and Low and Medium and Medium Medium
33 Medium and Low and Medium and High High
34 Medium and Low and High and Low Very Small
35 Medium and Low and High and Medium Small
36 Medium and Low and High and High Medium
37 Medium and Medium and Low and Low Small
38 Medium and Medium and Low and Medium Medium
39 Medium and Medium and Low and High High
40 Medium and Medium and Medium and Low Very Small
41 Medium and Medium and Medium and Medium Small
42 Medium and Medium and Medium and High Medium
43 Medium and Medium and High and Low Very Very Small
44 Medium and Medium and High and Medium Very Small
45 Medium and Medium and High and High Small
46 Medium and High and Low and Low Very Small
47 Medium and High and Low and Medium Small
48 Medium and High and Low and High Medium
49 Medium and High and Medium and Low Very Very Small
50 Medium and High and Medium and Medium Very Small
51 Medium and High and Medium and High Small
52 Medium and High and High and Low Very Very Small
53 Medium and High and High and Medium Very Small
54 Medium and High and High and High Small
55 High and Low and Low and Low Medium
56 High and Low and Low and Medium High
57 High and Low and Low and High Very High
58 High and Low and Medium and Low Very Small
59 High and Low and Medium and Medium Small
60 High and Low and Medium and High Medium
61 High and Low and High and Low Very Very Small
62 High and Low and High and Medium Very Small
63 High and Low and High and High Small
64 High and Medium and Low and Low Very Small
65 High and Medium and Low and Medium Small
66 High and Medium and Low and High Medium
67 High and Medium and Medium and Low Very Very Small
68 High and Medium and Medium and Medium Very Small
69 High and Medium and Medium and High Small
70 High and Medium and High and Low Very Very Small
71 High and Medium and High and Medium Very Small
72 High and Medium and High and High Small
674 H. Majumder, K. Maity / Applied Soft Computing 70 (2018) 665–679

Table 2 (Continued)

Rule IF THEN
no.
Ra Rq Rz ‘MH VFRG
condition condition condition

73 High and High and Low and Low Very Very Small
74 High and High and Low and Medium Very Small
75 High and High and Low and High Small
76 High and High and Medium and Low Very Very Small
77 High and High and Medium and Medium Very Small
78 High and High and Medium and High Small
79 High and High and High and Low Extremely Small
80 High and High and High and Medium Very Very Small
81 High and High and High and High Very Small

Fig. 19. Membership function of input output Mamdani system.

Fig. 20. Membership function for VFRG.

Fig. 21. Variation in VIKOR-Fuzzy reasoning grade (VFRG).
input parameters (see Fig. 22). For Ni-Ti SMA, the optimum input
parameter setting is TON : 10 ␮s, I: 12 A, WT: 12 N, WS: 150 mm/s
and FP: 6 bar.
Additionally, using MINITAB software, ANOVA test was exe-
cuted to determine the significant parameter effecting VFRG (see
Table 3). At a confidence level of 95%, the model was fitted, which is
a user defined criteria and can be modified as per the requirement
of the accuracy of the model used during the investigation. This
implies, if the value of the probability of acceptance is less than or
equal to 0.05 (P-value≤0.05), then the related parameter is said to
be statistically significant [57]. The significance of the input vari-
ables was assessed by their P-values. The influence of each input
parameter on VFRG was assessed by evaluating their percentage
contribution following Eq. (6).

Sum of square (SS)

into VFRG. Based on the MF and Fuzzy rules, the defuzzified multi-
characteristic performance index, i.e. VFRG are achieved. The crisp
value of VFRG is shown in Fig. 21.
6th Step: In the last step, the main effect plot of VFRG has been
carried out to determine the optimum combination of the WEDM
Percentage contribution = (6)
Total sum of square (SStotal )
The regression statistics, coefficient of determinant (R-sq) and
R-sq (adj) was found 92.80% and 90.32%, respectively. This signifies
that the VIKOR-Fuzzy model satisfactorily fitted the experimental
 H. Majumder, K. Maity / Applied Soft Computing 70 (2018) 665–679 675

Fig. 22. Main effect plot for VFRG.

Table 3
ANOVA analysis for VFRG.

Source DF SeqSS AdjMS F value P value % Contribution

Model 14 0.234117 0.016723 36.33 0 92.88

Linear 5 0.160434 0.032087 69.71 0 63.65
TON 1 0.075625 0.075625 164.29 0 30.00
I 1 0.052365 0.052365 113.76 0 20.77
WT 1 0.016598 0.016598 36.06 0 6.58
WS 1 0.013806 0.013806 29.99 0.258 5.48
FP 1 0.002040 0.002040 4.43 0.042 0.81
Square 5 0.070264 0.014053 30.53 0 27.87
TON *TON 1 0.015648 0.008894 0.015648 33.99 6.21
I*I 1 0.002475 0.002475 5.38 0.026 0.98
WT*WT 1 0.019067 0.019067 41.42 0 7.56
WS*WS 1 0.033040 0.033040 71.78 0 13.11
FP*FP 1 0.000034 0.000034 0.07 0.786 0.01
2-way Interaction 4 0.003419 0.000855 1.86 0.138 1.36
TON *FP 1 0.002838 0.002838 6.17 0.017 1.13
I*FP 1 0.000070 0.000070 0.15 0.699 0.03
WT*FP 1 0.000077 0.000077 0.17 0.685 0.03
WS*FP 1 0.000433 0.000433 0.94 0.338 0.17
Error 39 0.017953 0.000460 7.12
Total 53 0.252070 100.00
R-sq: 92.80% R-sq (adj): 90.32%

Table 4
Confirmation test results.

Optimal condition WEDM Responses

Ra (␮m) Rq (␮m) Rz (␮m) MH (HV)

Predicted TON 1 I3 WT2 WS1 FP1 2.28 9.67 14.25 374.40

Experimental TON 1 I3 WT2 WS1 FP1 2.04 8.96 13.57 395.22
Error 11.76% 7.92% 5.01% 5.56%

value. ANOVA table also shows the respective input parameters
influence on VFRG which indicates that pulse on time (TON ), is
the most effective for VFRG with 30% contribution. The regression
equation for VFRG is shown in Eq. (7).
VFRG = −1.322 + 0.2155 ∗ TON + 0.0875 ∗ I + 0.2248 ∗ WT
−0.01016 ∗ WS + 0.0352 ∗ FP
−0.00903 ∗ TON ∗ TON − 0.00359 ∗ I ∗ I − 0.00997 ∗ WT ∗ WT
(7)
+0.000026 ∗ WS ∗ WS − 0.00042 ∗ FP ∗ FP
−0.00272 ∗ TON ∗ FP + 0.00043 ∗ I ∗ FP + 0.00045 ∗ WT ∗ FP
−0.000047 ∗ WS ∗ FP
To analyze the adequacy of the proposed multivariate model, a
major diagnostic tool, residual analysis [58], was also carried out for
VFRG. Normal probability plot of the standardized residual, stan-
dardized residual versus fitted values, a histogram of standardized
residual and standardized residual versus observation order for the
proposed hybrid VIKOR-Fuzzy approach is shown in Fig. 23. By
observing the normal probability plot, it is evident that the most
of the residual points are following a straight line pattern which
indicates the fitness of the proposed model. The standardized resid-
ual of VFRG versus fitted value graph shows a random distribution
where residual points are located on both sides of the reference line.
In a histogram plot of standardized residuals, all the columns are
placed in a normal distribution. Fig. 22 also shows that standard-
ized residuals and observation orders are structure-less or does
 676
Table 5
Comparison of experimental results with state of the art.

Reference Prediction tool Material used Varying input Machining response Remarks

TON I WT WS FP Ra Rq Rz MH
√ √ √ √
Guven et al. [60] BPN, GRNN AISI 4340 steel plate × × × × × –
√ √ √
Kulekci et al. [61] MR AA7075 aluminum alloy × × × × × × –
√ √ √ √
Maher et al. [24] ANFIS AISI 1050 carbon steel × × × × × Cutting speed, HAZ
√ √ √
Shakeri et al. [62] Linear regression, Feed Cementation alloy steel 1.7131 × × × × × × Dimensional deviation, cutting
forward speed,
backpropagation
neural networks
√ √ √
Devarasiddappa et al. [63] ANN Inconel 825 × × × × × × –
√ √ √

H. Majumder, K. Maity / Applied Soft Computing 70 (2018) 665–679

Khan et al. [64] ANN Titanium alloy × × × × × × –
√ √ √
Caydas et al. [19] ANFIS AISI D5 tool steel × × × × × × WLT
√ √ √ √
Prasad et al. [65] ANN, MR Inconel 825 × × × × × –
√ √ √
Ugrasen e al [66]. ANN EN-31 × × × × × × Accuracy, MRR
√ √ √ √
Dey et al. [67] ANN Titanium × × × × × m/c rate, WWR, dimensional
deviation
√
Pradhan et al. [68] Neuro-Fuzzy, neural AISI D2 tool steel × × × × × × × × MRR, radial overcut, TWR
network
√ √ √
Gurupavan et al. [69] ANN, BPNN, LMA MMC × × × × × × Accuracy, MRR, EW
√ √ √ √
Reddy et al. [70] GRNN, BPN Cr-Mo-V alloyed steel × × × × × –
√ √
Pradhan et al. [34] GRNN AISI D2 tool steel × × × × × × × Radial overcut
√ √ √ √
Esme et al. [71] Neural network, DOE AISI 4340 steel. × × × × × –

Reference Optimization tool Material used Varying input Machining response Remarks

TON I WT WS FP Ra Rq Rz MH
√ √ √
Shabgard et al. [53] Fuzzy system Tungsten carbide × × × × × × MRR, TWR, Rk
√ √
Lin et al. [72] Fuzzy logics, Taguchi SKD11 × × × × × × × MRR, EWR
method
√ √ √ √
Sengottuvel et al. [49] Fuzzy, DFA Inconel 718 × × × × × MRR, TWR
√ √ √
Bhaumik et al. [22] Fuzzy, DFA AISI 304 stainless steel × × × × × × MRR, TWR
√ √
Tzeng et al. [50] Fuzzy, Taguchi SKD11 × × × × × × × Precision, accuracy
√ √ √ √
Puhan et al. [73] Fuzzy, PCA MMC × × × × × MRR, TWR, circularity
√ √ √
Dewangan et al. [74] Fuzzy, TOPSIS AISI P20 tool steel × × × × × × WLT, SCD
√ √ √
Lin et al. [21] Grey-Fuzzy × × × × × × EWR, MRR
√ √ √
Sivapirakasam et al. [23] Fuzzy, TOPSIS High carbon high chromium tool steel × × × × × × Process time,
Process energy,
REWR, dielectric
consumption,
concentration of
aerosol
√ √ √
Dewangan et al. [52] Fuzzy, GRA AISI P20 tool steel × × × × × × WLT, SCD
√
* : Considered in past research.
*×: Did not considered in past research.
*Remarks: Extra responses considered in past research.
 H. Majumder, K. Maity / Applied Soft Computing 70 (2018) 665–679
Fig. 23. Residual plot for VFRG for proposed VIKOR-Fuzzy approach.
not follow any pattern. Henceforth, it may be established that the
suggested model accomplishes satisfactorily [16,59].
6. Confirmation test
In the final stage, after attaining the optimal input parameter
combination by utilizing hybrid multivariate method VIKOR-Fuzzy,
a confirmation test was conducted to check the effectiveness of the
current approach. The percentage error in Ra, Rq, Rz and MH from
predicted values to experimental values for optimum setting were
measured from the confirmation test and listed in Table 4. The Ra
indicates a curtail value of 2.28 ␮m to 2.04 ␮m, the Rq shows a
curtail value of 9.67 ␮m to 8.96 ␮m, the Rz shows a curtail value
of 14.25 ␮m to 13.57 ␮m and MH shows an increased value of
374.40 HV to 395.22 HV. The corresponding improvement in Ra, Rq,
Rz and MH are 11.76%, 7.92%, 5.01% and 5.56%, respectively.
7. Comparison with state of the art
In this section, the authors tried to establish the difference
between proposed smart approximation tool GRNN and VIKOR cou-
pled with the Fuzzy logic system (hybrid optimization tool) with
state of the art. A few researchers predicted as well as optimized
key machinability responses in EDM using different soft comput-
ing techniques and Fuzzy optimization methods, which are listed
in Table 5.
8. Conclusions
In the experimental study, four WEDM responses were investi-
gated using five key input parameters for Ni-Ti shape memory alloy.
From this investigation following conclusions may be drawn:
1 The proposed GRNN model perceived approximately ±5% error,
which revealed the fitness of GRNN model to foresee the WEDM
outputs for Ni-Ti shape memory alloy.
2 The optimal parameter setting is perceived based on the
hybrid multivariate approach VIKOR-Fuzzy. Subsequently, the
input parameter combination of TON = 10 ␮s, I = 12 A, WT = 12 N,
677
WS = 150 mm/s and FP = 6 bar, were establish to provide the
favored results.
3 The proposed VIKOR-Fuzzy method can efficiently support the
decision makers in the manufacturing industry to define the opti-
mal input parameter combination for the WEDM operation for
Ni-Ti shape memory alloy under different conflicting response
criteria.
4 Analysis of variance results indicated that, for WEDM responses,
the pulse on time was the most important process parameter.
The recommended GRNN model and hybrid VIKOR-Fuzzy multi-
variate method can be applied to other WEDM responses like MRR,
kerf width, etc. It can also be used for different conventional manu-
facturing processes like welding, casting, turning, milling, etc. and
also for different non-conventional manufacturing processes like
LBM, AJM, USM, etc.
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