Micro-machining and Process Optimization of Electrochemical Discharge Machining (ECDM) Process by GRA Method

In recent years, the Electrochemical Discharge Machining (ECDM) process emerged as superseding machining process owing to its capability to processing of conductive and non-conductive materials. The micro-machining of Carbon Fibre Reinforced Polymer (CFRP) composite is successfully attempted in this work by drilling of micro-holes. The experiments were planned using L₉ orthogonal array Taguchi’s methodology with applied voltage, electrolyte concentration and inter-electrode gap as process parameters. The Material Removal Rate (MRR) and overcut rate were observed as output characteristics. Moreover, the multi-objective process optimization of ECDM process is carried out by Grey Relational Analysis (GRA) method. The conformation experiment with optimum conditions of GRA method such as applied voltage of 70 V, electrolyte concentration of 40% and inter-electrode gap of 50 mm signifies improvement in MRR and overcut rate of drilled hole.