Parametric optimization of USM parameters by Taguchi and NSGA-II for the development of µ-channels on pure titanium

Abstract

PurposeThis paper consolidates and presents the results of a work conducted to fabricate micro-channels on titanium grade-2 material by ultrasonic machining process (USM). In this research, the effects of important USM parameters, namely, kind of abrasives and its size, concentration of slurry, USM power rating and feed rate, have been probed on micro-channels quality for average surface roughness and process throughput in the form of material removal rate.Design/methodology/approachMultiple micro-channels on commercially pure titanium (i.e. Ti grade-2) have been fabricated in a single pass by employing micro-tool based USM process. Taguchi-based L18 (mixed level) OA has been selected for experimental design. Analysis of variance (ANOVA) study and regression modeling have also been done. Non-Dominated Sorting Genetic Algorithm (NSGA-II) has been used for process optimization to get optimum values of material removal rate (MRR) and surface roughness (SR).FindingsThe influence of important USM variables on SR and MRR have been investigated, and NSGA-II-based multi-response optimization has been done. The best surface roughness values obtained via NSGA-II solution for SiC and B4C are 0.354 µm and 1.303 µm, respectively. Scanned electron microscopic investigation proves the fabrication of micro-channels with smooth surfaces, and minimum burrs and other defects. The material removed from the surface was due to ductile fractures.Originality/valueMiniaturization is a modern trend these days to solve many precision, scientific and industrial problems. To manufacture precise micro-products, shapes and features, advanced and micro-machining processes can play a very prominent role. Micro-channels are typical micro-features required in micro-fluidic applications like micro heat exchangers and micro-pumps. Exhaustive review of existing research work indicated that precision micromachining of various materials can be effectively performed using USM, though not much work has been undertaken to explore the feasibility of multiple micro-channels in a single run using USM. The current work fulfills the gap, where multiple micro-channels on commercially pure titanium (i.e. Ti grade-2) have been fabricated in a single pass by employing micro-tool-based USM process.

NSGA-II-Based Microchannel Structure Optimization Problem Study

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Machining of Ti-6Al-4V biomedical alloy by WEDM: investigation and optimization of MRR and Rz using grey-harmony search

“…In recent years, numerous researchers (Statistical optimization) worked on multi-criteria decision-making (MCDM) approach to investigate and solve manufacturing-related issues, where more than one response characteristics (responses are contradictory) were involved. Gupta et al (2020 ) optimized the process parameters of micro ultrasonic machining using NSGA-II while developing micro-channels. Zarei et al (2009 ) used harmony search (HS) for the optimization of multi-pass face milling.…”