Optimization of Multiple Responses of Ultrasonic Machining (USM) Process: A Comparative Study

Abstract

Ultrasonic machining (USM) process has multiple performance measures, e.g. material removal rate (MRR), tool wear rate (TWR), surface roughness (SR) etc., which are affected by several process parameters. The researchers commonly attempted to optimize USM process with respect to individual responses, separately. In the recent past, several systematic procedures for dealing with the multi-response optimization problems have been proposed in the literature. Although most of these methods use complex mathematics or statistics, there are some simple methods, which can be comprehended and implemented by the engineers to optimize the multiple responses of USM processes. However, the relative optimization performance of these approaches is unknown because the effectiveness of different methods has been demonstrated using different sets of process data. In this paper, the computational requirements for four simple methods are presented, and two sets of past experimental data on USM processes are analysed using these methods. The relative performances of these methods are then compared. The results show that weighted signal-to-noise (WSN) ratio method and utility theory (UT) method usually give better overall optimisation performance for the USM process than the other approaches.

Keywords

• USM process
• Taguchi method
• Signal-to-noise ratio
• Optimization
• Multiple responses