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1 UDK :669.75:62.9 ISSN Orgal scetfc artcle/izvr zastve ~laek MTAEC9, 53(3)357(209) INTEGRATED STATISTICAL METHODOLOGY FOR OPTIMIZING THE MACHINING PARAMETERS IN SC POWDER MIXED EDDSG PROCESS TO MACHINE T6Al4V INTEGRIRANA STATISTI^NA METODOLOGIJA ZA OPTIMIZIRANJE PARAMETROV BRU[ENJA POVR[INE T6Al4V ZLITINE Z EDDSG PROCESOM V ME[ANICI S SC PRAHOM Maoj Mod *, Gopal Agarwal 2 Departmet of Mechacal Egeerg, Acropols Isttute of Techology ad Research, Idore, Ida 2 Departmet of Mechacal Egeerg, Malavya Natoal Isttute of Techology, Japur, Rajastha, Ida Prejem rokopsa receved: ; sprejem za objavo accepted for publcato: do: /mt The objectve of ths research work was targeted to vestgate the hybrd-statstcal methodology to deduce the ecoomcalmachg-codto through mult-output optmzato slco carbde powder mxed-electro Dscharge Damod Surface Grdg of T6Al4V. I ths work, Grey-Fuzzy based prcpal compoet aalyss alog wth Taguch s orthogoal array s utlsed for the mult-output optmzato of hybrd-machg process parameters for mmal surface roughess, mmal wheel-wear rate, ad maxmal materal removal rate. Eghtee expermets have bee coducted accordg to Taguch s L 8 orthogoal array o -house-desged ad fabrcated powder mxed-electro Dscharge Damod Surface Grdg set-up. The sgle Mult-Output Performace Idex s calculated by the aggregato of all mult-resposes by usg Grey-Fuzzy-Taguch method based prcpal compoet aalyss fucto. The optmum combato of process parameters ad the effect of these parameters o the Mult-Output Performace Idex are determed by the use of ANOVA aalyss ad respose table. For the valdato test, oe addtoal cofrmato expermet s coducted o ths set-up accordg to the derved optmal codto ad the outcomes of the results showed satsfactory matchg betwee the predcted ad expermeted result. The specfc cotrbuto of ths research work s to develop ad descrbe the procedure of tegrated statstcal methodology for mult-output optmzato of machg parameters powder mxed-electro Dscharge Damod Surface Grdg of T6Al4V. Ths tegrated statstcal approach hybrdzes the cocepts of Grey Relatoal Aalyss, Fuzzy, prcpal compoet aalyss ad Taguch approach to fd the optmum combato of machg parameters for ecoomcal machg. Ths optmum combato of process parameters supports egeers to establsh a ecoomcal ad effectve process. Keywords: aalyss of varace (ANOVA), powder mxed-electro dscharge damod surface grdg (PM-EDDSG), hybrd process, grey relatoal aalyss, fuzzy, prcpal compoet aalyss (PCA), Taguch s method (TM), T-6Al-4V Pr~ujo~ ~laek opsuje razskavo hbrde statst~e metodologje za dolo~tev ekoom~h pogojev mehaske obdelave z ve~kompoeto aalzo optmzacje zhodh podatkov bru{eja povr{e T6Al4V zlte s tako meovam postopkom PM-EDDSG (damato bru{eje povr{e z elektro erozjo v me{ac prahu). V tem delu je uporabljea osova kompoeta aalza, k temelj a tako meova svo-zabrsa logk (agl.: Grey-Fuzzy) v kombacj s Taguchjevo ortogoalo matrko, s katero aj b apovedal zhode pogoje za dosegaje mmale povr{ske hrapavost, mmale obrabe bruslega koluta maksmalo htrost odstrajevaja materala pr hbrd mehask obdelav s PM-EDDSG postopkom. Avtorj so zvedl osemajst ekspermetov v skladu s Taguchjevo L 8 ortogoalo matrko a doma dzajraem zdelaem stroju za PM-EDDSG postopek. Posameze ve~zhod deks u~kovtost (MOPI; agl.: Mult-Output Performace Idex) so zra~ual z zdru`tvjo vseh ve~krath odzvov z uporabo G-F-T metode (agl.: Grey-Fuzzy-Taguch method), k temelj a kompoet fukcjsk aalz. Optmalo kombacjo procesh parametrov vplv teh parametrov a MOPI so dolo~l z uporabo ANOVA aalze tabele odzvov. Kot valdacjsk test so zvedl {e e dodat ekspermet a pr~ujo~ aprav pr dobljeh optmalh pogojh. Rezultat prezkusa so pokazal zadovoljvo ujemaje med apovedam z ekspermetom dobljem rezultat. Specf~ prspevek tega razskovalega dela je razvoj ops postopka tegrrae statst~e metodologje za ve~ zhodo optmzacjo parametrov mehaske obdelave povr{e T6Al4V zlte s PM-EDDSG postopkom. Ta tegrra statst~ prstop zdru`uje kocepte svo-zabrsae relacjske aalze (agl.: Grey-Fuzzy Relatoal Aalyss), osove kompoete aalze Taguchjeve metode za dolo~tev optmale kombacje procesh parametrov ekoom~e mehaske obdelave. Ta optmala kombacja procesh parametrov omogo~a procesm `erjem uvajaje ovega ekoom~ega u~kovtega procesa. Klju~e besede: aalza varace (ANOVA), damato bru{eje povr{e z elektroerozjo v me{ac prahu (PM-EDDSG), hbrd proces, sva relacjska aalza, zabrsaost, osova kompoeta aalza (PCA), Taguchjeva metoda (TM), T-6Al-4V INTRODUCTION *Correspodg author e-mal: maojmtjapur@gmal.com Powder Mxed-Electro Dscharge Damod Surface Grdg s a emergg hybrd process for the machg of hard materals lke T6Al4V. Ths materal s wdely utlzed varous applcatos, cludg bomedcal, automotve, etc. L et al. dd expermetato o the Electrcal Dscharge Machg of SKD steel ad reported that the materal removal rate ad electrode wear rato are mproved together by usg a Taguch- Fuzzy logc approach for solvg the mult-output optmzato problem. Kug et al. 2 coducted expermetato o Powder Mxed Electrcal Dscharge Machg of 94WC-6Co ad developed the models for materal Materal tehologje / Materals ad techology 53 (209) 3,

2 removal rate ad electrode wear rato by Respose Surface Methodology. Further, they studed the fluece of put varables o the resposes. Sgh et al. 3 coducted expermetato o the Electro Dscharge Face Grdg of WC-Co ad studed the fluece of process varables over the resposes. L et al. 4 carred out expermetato o the Electrcal Dscharge Machg of SKD steel ad showed that a combed Grey Relatoal Aalyss-orthogoal array approach ehaces the machg performace mult-output optmzato. Ths combed methodology mproves the process outputs,.e., electrode wear rato, materal removal rate ad surface roughess the Electrcal Dscharge Machg process. Targ et al. 5 carred out expermets ad reported the use of the Taguch approach to fd the optmum combato of weldg varables the submerged arc-weldg of mld steel plates. Ko et al. 6 appled a Grey Relatoal Aalyss ad the Fuzzy-orthogoal array method o Electrcal Dscharge Machg, Tzeg et al. 7 appled the Fuzzy-Taguch method o Electrcal Dscharge Machg ad L et al. 8 appled Grey-Fuzzy method o Electrcal Dscharge Machg for the mult-output optmzato of process varables. George et al. 9 appled the Taguch method to fd the optmum combato of process varables o Electrcal Dscharge Machg of C-C compostes. Fug et al. 0 performed expermetal work ad preseted the use of the prcpal compoet aalyss-taguch approach for the optmzato of mult-output, fber-reforced polybutylee terephthalate compostes. Alagumurth et al. have coducted expermetal work o the grdg of mld steel ad compared the factoral desg of expermet wth the Taguch desg of expermet approach, used to fd the optmal grdg codtos. They reported that depth of cut, wheel speed ad work speed were mportat grdg parameters that affect the grdg qualty. Jea et al. 2 coducted expermetal work ad reported the use of a prcpal compoet aalyss-taguch approach to develop a robust Electro Beam Weldg Treatmet process wth hgh effcecy multple-performace characterstcs (MPCs). Dutta et al. 3 coducted expermetato o Wre Electrcal Dscharge Machg of D2 tool steel. They appled Respose Surface Methodology to develop the models for each respose ad these models were used to predct the behavour of process varables o the resposes. They appled Grey Relatoal Aalyss-Taguch methodology to fd the optmal varables settg mult-respose optmzato. Lahae et al. 4 dd expermetal work ad proposed a Weghted Prcpal Compoet method for mult-outputs optmzato of the process factors the wre Electrcal Dscharge Machg of HSS steel. V. K. Ja 5 reported that Hybrd Machg Process performace s more effectve as compared to separate performace of compoet process wth smlar put varables. Based o the above lterature revew, there s the ecessty for effcet optmzato methodology to take care of the problems related to the co-occurrg optmzato of mult-correlated resposes ad ther solutos. Taguch s methodology has bee broadly utlzed for process parameters optmzato. Ths techque s beefcal for sgle respose optmzato, however, effectve to optmze the mult-resposes. I ths research work, Taguch s method s tegrated wth Grey-fuzzy based prcpal compoet aalyss to beat the drawback maagg the dffculty of the smultaeous optmzato of mult-correlate resposes. Ths tegrated statstcal methodology s utlzed to derve a detcal equvalet process-qualty dex by combg the mult-resposes to depct the overall qualty of the process so that the dffculty of cocurret optmzato of mult-resposes s substtuted by the problem of maxmzg the process - Overall Qualty Idex. That s why Taguch s Utlty-Theory ca be effcetly utlzed to maxmze the process overall qualty. I ths research work, a uque tegrated mult-output optmzato methodology s plaed to deduce the optmum combato of machg varables the Powder Mxed-Electro Dscharge Damod Surface Grdg of T6Al4V. Ths tegrated methodology hybrdzes the cocepts of Grey, Fuzzy, Prcpal Compoet-Aalyss ad Taguch to take care of the problem of co-occurrg optmzato of three correlatve Powder Mxed-Electro Dscharge Damod Surface Grdg process performace measures lke materal removal rate, surface roughess, ad wheel wear rate machg of T6Al4V. 2 METHOD FOR MULTI-OUTPUT-OPTIMIZA- TION 2. Grey Relatoal Aalyss Method I Grey Relatoal Aalyss, the tal step s to ormalze the expermetal data betwee zero-to-oe by usg Equatos () ad (2). For materal removal rate, the hgher s the better crtero s selected. Smlarly, for surface roughess ad wheel wear rate, the lower s the better crtero has bee selected. 6 For hgher s the better crtero (H-T-B), ( 0) ( 0) x () t m x () t * x () t = ( 0) ( 0) () max x () t m x () t For lower s the better crtero (L-T-B), ( 0) ( 0) max x () t x () t * x () t = ( 0) ( 0) (2) max x () t m x () t ( where, x 0 ) ()= t orgal sequece, x (*) ()= t value after the Grey Relatoal ormalzato, m x ( 0 ) ()= t lowest ( value of x 0 ) (), t max x ( 0 ) ()= t maxmum value of x ( 0 ) t (), =, 2,..., p; t =, 2,..., q, p = total expermet ad q = 358 Materal tehologje / Materals ad techology 53 (209) 3,

3 total observato data. The ext step s to determe the devato sequece [Δ o ()] t for every output ( = 0.5) ad the the Grey Relatoal Coeffcet s determed by usg Equato (3). * * m + max ( xo (), t x () t ) = Δ Δ (3) Δ ()+ t Δ Δ = max * * ( ) o max xo (), t x () t, Δ o ()= t x * o (), t x * () t, * * max max x (), t x (), t Δ = m m x (), t x (). t j t * * o j m j t s the dstgushg coeffcet, [ ] 0,. Where, x * o ()= t Referece sequece ad x * ()= t Comparablty sequece. I the fal step, the Grey Relatoal Grade s determed by usg Equatos (4) ad (5) ad ts log S value s calculated for the hgher s the better (H-T-B) cocept. q q ( x (*) (*) ) ( (*) (*) o, x = t xo ( t), x ( t) ) t= q t = t= o j (4) (5) where q s the umber of process resposes. The Grey Relatoal Grade shows the terrelato betwee x (*) () o t ad x (*) (). t 2.2 Taguch s Method Taguch s Method s a techque usually used to frame-up the orthogoal array of expermets, wth less varace betwee the expermet outcomes. Ths methodology ot oly helps to develop the orthogoal array but also mmze the umbers of expermetal rus, eough to optmze ad aalyze the process. There are three kds of sgal-to-ose ratos: lower s the better (L-T-B), hgher s the better (H-T-B), ad omal s the better (N-T-B), whch s expressed mathematcal forms by Equatos (6), (7) ad (8). A ANOVA aalyss s utlzed for data-aalyss to vestgate the effect of ma machg varables o the output resposes. Lower s the better (L-T-B), 2 l = 0 log y (6) = Hgher s the better (H-T-B), l = 0 log 2 y (7) = Nomal s the better (N-T-B), 2 l = 0 log y (8) s = where y s the measured output respose at the th tral, s the total umber of expermetal-rus, l s the lossqualty fucto at the th tral ad s deotes the stadard devato. 2.3 Prcpal Compoet Aalyss Prcpal Compoet Aalyss was troduced by Pearso ad Hotellg (933). Ths methodology s utlzed to defe the varace ad covarace relato wth the help of lear composto of orgal parameters. The PC descrbes the maxmal varace the collected data ad the PC 2 descrbes the remag varace that was left by the PC ad so o. Suppose, the systemvarablty s depcted by the p-compoets. The system varablty may be descrbed by a smaller umber, m (m p), of the PCs,.e., m PCs ca accout for the majorty of varace wth the orgal p parameters. For the respose varables, Z, Z 2 Z p, there s the followg PCs Y ( =, 2, 3,..., p). Y = a Z + a Z a Z 2 2 Y = a Z + a Z a Z p Ym = amz + am2z amp Z p where am + am amp = Here, Y s kow as frst prcpal compoet, Y 2 s kow as the secod prcpal compoet ad so o. The m th compoet coeffcet s the parts of the egevector matchg to the m th bggest egevalues. The prcpal compoet aalyss ca be doe o MINITAB software. Prcpal Compoet Aalyss s a effectve methodology to descrbe the slght umber of compoets that s resposble for the prcpal sources of varato a set of correlated-qualty characterstcs. The procedure of Prcpal Compoet Aalyss s as follows: a) Calculate the sgal-to-ose rato for every outputrespose by Equatos (6) to (8). b) Normalze the sgal-to-ose rato of every output resposes to 0 to by the use of Equatos () ad (2). c) Carry out prcpal compoet aalyss o the ormalzed data. d) Determe the ege-values, ad ege-vectors. e) Calculate the umbers of PCs, m, ad compute. 2.4 Fuzzy Method I ths methodology, the fuzzy reasog grade (FRG 0 ) s calculated by the use of the max-m fuzzy terface ad the cetrod defuzzfcato methods. The system of Fuzzy Logc cotas 5 compoets; Fuzzfer, Membershp Fucto, Rules, Iferece System, ad Defuzzfer. The fuzzy-logc-terface system for ths research work s developed usg MathWorks TM MATLAB (Release 203a), Fuzzy Logc Toolbox. Here, the basc structure of the fuzzy logc ut for two fuzzy puts wth oe fuzzy output s dsplayed Fgure. Fuzzy lgustc descrpto s the formal presetato of systems made through fuzzy IF-THEN rules. p p p Materal tehologje / Materals ad techology 53 (209) 3,

4 Fgure : Basc structure of fuzzy logc ut Rule oe: IF (Y s E ) ad (Y 2 s G ) the (Z s F ) else Rule two: IF (Y s E 2 ) ad (Y 2 s G 2 ) the (Z s F 2 ) else Rule twety fve: IF (Y s E 25 ) ad (Y 2 s G 25 ) the (Z s F 25 ) else μ E, μ G ad μ F are the membershp fuctos correspodg to the E,G ad F fuzzy subsets. I ths research work, fve fuzzy-subsets are allotted to two puts ad e fuzzy subsets are allotted to the output as dsplayed Fgure 4. The total possble umber of fuzzy rules used here s twety-fve. These fuzzy rules are obtaed wth the evdece that a bgger log S value correspods to the major beeft to the process output. Suppose, Y ad Y 2 are the values of the puts, the membershp fucto of the mult-output Z ca be dsplayed by Equato (9). F Z ( E Y G Y F Z) 0 2 ( E ( Y) G ( Y2) ( Z) ) ( ) = ( ) ( ) ( )... F (9) Here, s related to mmal ad s related to maxmal operato. For the defuzzfcato, cetre-of-gravty methodology s used, whch covert mult-output μ C0 (Z) to crsp fuzzy reasog grade (FRG 0 ) usg Equato (0). Fgure 2: Methodology of Itegrated Statstcal Grey-Fuzzy-TM based PCA Approach 360 Materal tehologje / Materals ad techology 53 (209) 3,

5 FRG 0 = Z F0 F0 ( Z) ( Z) (0) 3 METHODOLOGY FOR AN INTEGRATED GREY-FUZZY-TAGUCHI-BASED PCA APPROACH The detal procedure for a tegrated Grey-Fuzzy- Taguch-based PCA method s show Fgure 2. 4 EXPERIMENTAL PART Eghtee expermets were coducted accordg to Taguch s L 8 orthogoal array o -house-desged ad fabrcated slco carbde Powder Mxed-Electro Dscharge Damod Surface Grdg set-up. All the detals of the Powder Mxed-Electro Dscharge Damod Surface Grdg set-up are avalable at Mod et al. 7 The schematc-photographc dagram of Powder Mxed- Electro Dscharge Damod Surface Grdg frame-up s dsplayed Fgure 3. The varous put parameters lke powder cocetrato (gm/l), curret (A), pulse-o-tme (μs), wheel-speed (m ) ad duty cycle (DC) were selected for the expermetal vestgato. Depedg upo the tal expermetal results ad Electrcal Dscharge Machg capacty, the varables rage was selected as dsplayed Table. Table : Varous put varables ad ther levels Symbol Cotrol Factor Level Level 2 Level 3 P-C SC Powder Cocetrato (gm/l) 2 4 I Curret (A) 5 9 T o Pulse-o-tme (μs) S Wheel Speed (m ) DC Duty Cycle The detaled descrpto of the broze-damod wheel s dsplayed Table 2. Table 2: Detal descrpto of broze-damod grdg wheel Damod 00 mm Abrasve Dameter Thckess Bod materal Cocetrato Bore 0 mm Broze 75 % 32 mm Depth of abrasve Grt sze 5 mm 80/00 I ths expermetato, the work-pece materal was T6Al4V. The work-pece s flat ad rectagular shape. The composto of T-6Al-4V (grade-5) s Carbo = 0.02 %, Al = 6.05 %, T = 90. %, V=3.7% ad Fe = 0.3 %. The slco carbde powder s added to the delectrc flud of the EDDSG set-up. The powder partcle sze s approxmately #30 μm ad the cocetrato rage s from 2 gm/ltre to 4 gm/ltre. Equato () was used to calculate the materal removal rate ad wheel wear rate for each machg process. MRR WWR ( mg / m) = DWW t 00 () DWW s the dfferece the work-pece/wheel weght before ad after the machg tme equal to 30 m. The materal removal rate ad wheel wear rate were measured by usg the Hgh Precso Electroc Balace, WENSAR, HPB-30 Model. The surface roughess of the mached work-pece was measured by the Surtroc-25 surface roughess tester at the cut-off value of 0.8 mm. The dgtal tachometer was used for the grdg wheel speed measuremet. Fgure 3: Schematc dagram of -house-desged ad fabrcated Powder Mxed-Electro dscharge damod surface grdg set-up Fgure 4: a) Membershp fucto of puts, b) Membershp fucto of output, c) Fuzzy-Iterface system at 2-level Materal tehologje / Materals ad techology 53 (209) 3,

6 Table 3: L 8 orthogoal array, output resposes, log S value, ad ormalsed log S value Cotrol Factor Resposes log S value Normalzed log S value Exp. No P-C I T o S DC MRR R a WWR (mg/m) (μm) (gm/m) MRR R a WWR MRR R a WWR PROCESSING OF EXPERIMENTAL DATA Here, Table 3 dsplays the L 8 orthogoal array, output resposes, log S value, ad ormalsed log S value. Table 4 dsplays the devato sequece ad Grey Relatoal Coeffcet. Table 5 dsplays the egevalues, egevector. Table 6 dsplays the fuzzy rules. Table 7 dsplays the prcpal compoets ad mult-output performace dex ad Table 8 dsplays the respose ad ANOVA for mult-output performace dex. Fgure 5 dsplays the fuzzy logc reasog procedure for the test result 8; Fgure 6 dsplays the surface plot of mult-output performace dex wth puts; Fgure 7 dsplays the % cotrbuto of machg processparameters o mult-output performace dex, ad Fgure 8 dsplays the sgal to ose-rato plot of multoutput performace dex. Calculato of the devato sequece ad Grey Relatoal Coeffcet (GRC). Table 4: Dsplays the devato sequece ad GRC Exp. No. Devato sequece GRC MRR R a WWR MRR R a WWR Prcpal Compoet Aalyss for egevalue ad egevector. Fgure 5: Fuzzy logc reasog procedure for the test result Materal tehologje / Materals ad techology 53 (209) 3,

7 Table 5: Dsplays the egevalues, ad egevector PC PC 2 PC 3 Egevalue Egevector [0.640, 0.68, [ 0.383, 0.7, [ 0.666, 0.722, 0.354] 0.96] 0.86] Proporto Cumulatve Prmarly, the prcpal compoets (PCs) are dvded to two categores wth egevalue > ad egevalue <. MPI- s calculated through PC 2 ad PC 3 as put wth egevalue <. Fal mult-output performace dex s calculated through PC ad MPI- as the put by usg the smlar membershp fuctos ad rules. Table 6: Twety-fve fuzzy rules tabular form MPI Iput 2 Iput VS S M L VL VS T VS S SM M S VS S SM M ML M S SM M ML L L SM M ML L VL VL M ML L VL H Table 7: Prcpal Compoets ad mult-output performace dex (MPI) Prcpal Exp. compoets Normalse PCs o. MPI- MPI PC PC 2 PC 3 PC PC 2 PC The Fuzzy logc reasog procedure for the test result 8 s dsplayed Fgure 5. The surface plot of the mult-output performace dex s dsplayed Fgure 6. Calculato of mult-output performace dex (MPI). 6 RESULTS AND DISCUSSION The ANOVA test was performed o the mult-output performace dex. The fluece of varous machg process parameters o the mult-output performace dex ad the ANOVA aalyss result s dsplayed Table 8. The optmum combato of varous process parameters obtaed through the tegrated statstcal optmzato method for the mult-output optmzato Powder Mxed-Electro Dscharge Damod Surface Grdg of T6Al4V, s powder cocetrato wth level oe; curret wth level three; pulse-o-tme wth level three; the speed wth level two ad duty cycle wth level three. For the valdato test, oe addtoal cofrmato expermet was performed o ths set-up accordg to Fgure 6: Surface Plot of MPI wth puts the derved optmal codto ad the outcomes of the result showed satsfactory matchg betwee predcted ad expermeted results. The cofrmato test result s lsted Table 9, whch dsplays the closure correlato betwee the expermetal ad predcted values. A Scag Electro Mcroscopy vestgato has bee coducted o the produced mache surface through slco carbde powder mxed-electro Dscharge Damod Surface Grdg process uder optmal cod- Table 8: Respose ad ANOVA for mult-output performace dex (MPI) Respose table ANOVA table Symbol Level Level 2 Level 3 Max-M DF SS MS F P C (%) 8.8 p P-C p I p T ON p S p DC Error Total Materal tehologje / Materals ad techology 53 (209) 3,

8 Fgure 7: Percetage cotrbuto of machg process parameters o MPI Table 9: Result of cofrmato test Factor Level tos. Fgure 9 dsplays the SEM mage of the: a) produced mached surface at optmum codto (I =9A, T o = 200 μs, DC = 0.77, S = 550 m, P-C =2gmof powder/l); b) Whte recast layer thckess at optmum codto (I =9A,T o = 200 μs, DC = 0.77, S = 550 RPM, P-C = 2 gm of powder/l). These mages revealed that satsfactory output-resposes are acqured through the suggested tegrated statstcal methodology. 6. Cofrmato test The estmated grade Fgure 8: S/N-rato plot of MPI Ital Process Optmal Process parameter Parameters Predcto Expermet PC I T o S D PC I 3 T o3 S 2 D 3 PC I 3 T o3 S 2 D 3 MRR (mg/m) R a (μm) WWR (gm/m) MPI Improvemet MPI s = + ( ) m m = (2) Fgure 9: a) SEM mage of the produced mached surface Powder Mxed - EDDSG process wth SC powder uder optmum codtos (I =9A,T o = 200 μs, DC = 0.77, S = 550 m, P-C =2gmof powder/l), b) SEM mage of wrlt thckess wth SC powder uder optmum codtos (I =9A,T o = 200 μs, DC = 0.77, S = 550 m, P-C = 2 gm of powder/l). where m s the average grade, s the optmum level average grade ad š s the total sgfcat desg varables that affect the mult-output respose. To esure the ehacemet qualty performace, a cofrmato test s performed. The outcome of ths test s dsplayed Table 9. 7 CONCLUSIONS I ths research paper, a tegrated statstcal methodology of Grey-Fuzzy-Taguch s Method based prcpal compoet aalyss has bee utlzed for mult-output optmzato of the machg parameters slco carbde powder mxed-electro Dscharge Damod Surface Grdg processes of T6Al4V. The sgle mult-output performace dex s calculated by the aggregato of all mult-resposes through Grey-Fuzzy-Taguch s Methodbased prcpal compoet aalyss fucto. Hece, ANOVA s appled o mult-output performace dex to calculate the sgal-to-ose rato wth Hgher s the Better crtero. The followg coclusos could be draw based o the aalyss of outcomes obtaed through the suggested approach ad SEM mage vestgatos: 364 Materal tehologje / Materals ad techology 53 (209) 3,

9 . The optmal level of machg process parameters derved from the tegrated statstcal methodology of Grey-Fuzzy-Taguch s Method-based prcpal compoet aalyss approach are: 2 gm/l of powder cocetrato; 9Aofcurret; 200 μs of pulse-o-tme; 550 revoluto per m (m ) of wheel speed ad 0.77 of duty cycle. 2. The expermetal results of output resposes uder optmal codto are materal removal rate equal to.86 mg/m; R a equal to 6.00 μm; ad wheel wear rate equal to gm/m. 3. It s observed through ANOVA results that the percetage cotrbuto of varous process parameters o the process performace s powder cocetrato (0.26 %); curret (82.47 %); pulse-o-tme (0.9 %); wheel speed (8.05 %); ad duty cycle (9.02 %). The curret s the most sgfcat parameter that affects the process performace. 4. The Mult-output Performace Idex has bee mproved by The SEM outcomes also equally satsfy the predcted outcomes from the suggested tegrated statstcal methodology. The suggested tegrated statstcal method may also be utlzed to optmze the problem of the co-occurrg optmzato of mult-correlated resposes some other producto machg processes to mprove the producto effcecy ad also automate the producto machg process based o the calculated optmum values. Nomeclature ANOVA Aalyss of varace PM-EDDSG Powder Mxed-Electro Dscharge Damod Surface Grdg HM Hybrd Machg EDG Electro Dscharge Grdg EDM Electrcal Dscharge Machg HMP Hybrd Machg Process RSM Respose Surface Methodology DC Duty Cycle (%) DWW Dfferece work-pece/wheel weght before ad after the machg WEDM Wre Electrcal Dscharge Machg I Curret (A) MRR Materal Removal Rate (mg/m) WWR Wheel Wear Rate R a Average Roughess of Surface (μm) MIN Revoluto per mute S Wheel Speed (MIN ) T o Pulse o-tme (μs) t Tme m Desty of work-pece materal (gm/cm 3 ) P-C Powder Cocetrato OA Orthogoal Array CM Correlato Matrx GRA Grey Relatoal Aalyss PCA a mp TU-Theory OQI H-T-B L-T-B N-T-B GRC GRG TM PC/PC S MF/MF S MPI 8 REFERENCES Prcpal Compoet Aalyss m th elemet the p th ege vector Taguch s Utlty Theory Overall Qualty Idex Hgher s the better Crtero Lower s the better Crtero Nomal s the better Crtero Grey Relatoal Coeffcet Grey Relatoal Grade Taguch s Method Prcpal Compoet / Prcpal Compoets Membershp Fucto/Membershp Fuctos Mult-output Performace Idex J. L. L, K. S. Wag, B. H. Ya, Y. S. Targ, Optmzato of the electrcal dscharge machg process based o the Taguch method wth fuzzy logcs, Joural of Materals Processg Techology, 02 (2000), 48 55, do:0.06/s (00) K. Y. Kug, J. T. Horg, K. T. Chag, Materal removal rate ad electrode wear rato study o the powder mxed electrcal dscharge machg of cobalt-boded tugste carbde, It J Adv Mauf Techol., 40 (2009), 95 04, do:0.007/s G. K. Sgh, V. Yadava, R. Kumar, Damod face grdg of WC-Co composte wth spark assstace: Expermetal study ad parameter optmzato, Iteratoal Joural of Precso Egeerg ad Maufacturg, (200) 4, , do:0.007/ s J. L. L, C. L. L, The use of orthogoal array wth grey relatoal aalyss to optmze the electrcal dscharge machg process wth multple performace characterstcs, Iteratoal Joural of Mache Tools & Maufacture, 42 (2002), , do:0.06/ S (0) Y. S. Targ, W. H. Yag, Applcato of the Taguch method to the optmzato of the submerged arc weldg process, Materals ad Maufacturg Processes, 3 (998) 3, , do:0.080/ T. C. Ko, J. L. L, C. L. L, Optmzato of the EDM process based o the orthogoal array wth fuzzy logc ad grey relatoal aalyss method, It J Adv Mauf Techol., 9 (2002), , do:0.007/s Y. F. Tzeg, F. C. Che, Mult-objectve optmzato of hgh-speed electrcal dscharge machg process usg a Taguch fuzzy-based approach, Materal ad Desg, 28 (2007), 59 68, do:0.06/ j.matdes J. L. L, C. L. L, The use of grey-fuzzy logc for the optmzato of the maufacturg process, Joural of Materals Processg Techology, 60 (2005), 9 4, do:0.06/j.jmatprotec P. M. George, B. K. Raghuath, L. M. Maocha, A. M. Warrer, EDM machg of carbo-carbo composte ataguch approach, Joural of Materals Processg Techology, 45 (2004), 66 7, do:0.06/s (03)00863-x 0 C. P. Fug, P. C. Kag, Mult-respose optmzato frcto propertes of PBT compostes usg Taguch method ad prcple compoet aalyss, Joural of Materals Processg Techology, 70 (2005), , do:0.06/j.jmatprotec N. Alagumurth, K. Palaradja, V. Soudararaja, Optmzato of grdg process through desg of expermet (doe) a comparatve study, Materals ad Maufacturg Processes, 2 (2006), 9 2, do:0.08/amp Materal tehologje / Materals ad techology 53 (209) 3,

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