Trends in Opto Electro & Optical Communications

ISSN: 2231-0401(online), ISSN: 2347-9957(print)

Volume 6, Issue 3
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Multi-variable Analysis and Optimization of Electrical

Discharge Machining Process Using a PCA-ANN Based
Approach
Kaushal Pratap Singh*, Brij Kishor Singh, Manoj Kumar Gaur
Department of Mechanical Engineering, Madhav Institute of Technology and Science, Gwalior,
Madhya Pradesh, India

Abstract
The optimum selection of process parameters has played a crucial role in electrical discharge
machining (EDM) for improving the material removal rate, reducing the tool wear rate and
radial overcut. In this paper, optimum parameters while machining 202 stainless steel using
copper electrode as a tool has been investigated. For optimization of process parameters
along with multiple quality characteristics, principal component analysis coupled with
artificial neural network method has been adopted in this work. Here artificial neural network
(ANN) is used to predict the combined objective function (COF). Comparison between
experimental COF with ANN predicted COF to find the percentage error.

Keywords: Response parameter (MMR, TWR, SR), EDM, PCA, ANN, COF

*Author for Correspondence E-mail: brijanangpal@gmail.com

INTRODUCTION multi-objective problem. This paper deals with

In the world of machining and most
importantly in manufacturing of mould and die
components, machining of hardened steel is a
vital area for today’s scientific research. For
machining of hardened steel, the preferred
metal cutting process is electrical discharge
machining. This process is characterized by
good material removal rate, better dimensional
accuracy and up to the mark surface finish. In
practice, optimization of every machining
process parameter is usually is a challenging
task, because it requires simultaneously both,
machining operation experience and
knowledge of mathematical algorithms. The
problem of optimization in EDM is very
complex in nature and number of constraints
has to be considered at a time. Considering
this fact, process parameter optimization in
electrical discharge machining becomes a
influential parameters for EDM, thirty two
experiments have been carried out based on
full factorial design (25) in order to have
representative data. Application of principal
components analysis (PCA) (Table 3) coupled
with artificial neural network to effect of
process parameters simultaneously on the
performance characteristics during EDM of
202 stainless steel, and also to predict the
combined objective function using artificial
neural network which is used to calculate the
percentage error. The experimental analysis
using the proposed approach gave the
optimized and profitable result. The
framework for literature review is presented in
Table 1.
FRAMEWORK FOR LITERATURE
REVIEW

Table 1: Summary of Literature Review and Experts’ Opinion.

Author/Year Process Parameters Performance Measures Remarks
Gangadharudu Powder concentration, peak Maximum MRR and A multi response optimization was
et al. (2015) current, pulse on time and minimum Ra also performed using principal
duty cycle component analysis-based grey
technique (Grey-PCA) to determine
optimum settings of process
parameters [1].

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Multi-variable Analysis and Optimization of EDM Process Singh et al.

Shailesh et al. Discharge current, pulse on Formation of white layer Multi objective optimization of
(2014) time, duty cycle and polarity and surface crack density various EDM parameters for obtaining
and SR favourable preference measures in
surface integrity) using PCA based
grey relational analysis has been
selected [2].
To develop an appropriate machining
Sameh et al. Pulse duration, peak current Material removal rate, tool strategy for a maximum process
(2014) and tool electrode rotational electrode wear rate and criteria yield. A feed-forward back-
speed surface roughness propagation neural network was
developed to model the machining
process [3].
Ranjan et al. Current, time MRR, surface finish Artificial neural network (ANN) is
(2014) adopted. This study addresses the
modeling of machinability of WP7V
[4].
Jagadish et al. Peak current, pulse duration, Process time, relative tool The optimal process parameters using
(2014) dielectric level, and flushing wear ratio, process energy, the GRA approach. The weighting
pressure. concentration of aerosol, values corresponding to various
dielectric consumption performance characteristics are
determined using PCA [5].
Milan et al. Gas pressure, arc current, MRR, surface finish WPCA is applied to compute a multi-
(2014) torch height response performance index (MPI)
and then MPI has been optimized
using Taguchi method [6].

Pulse current (Ip), discharge
Hargovind et al. time (Ton), duty cycle (Tau)
(2013)
Cakir et al. Discharge current, pulse on-
(2013) time, pulse off-time
Tzeng and Chen Discharge current, gap
(2013) voltage, pulse on-time, pulse
off-time
Rina et al. Work-piece polarity, pulse-
(2012) on-time, duty factor, open
discharge voltage, discharge
current and dielectric fluid
Material removal rate,
surface roughness, and
radial overcut
MRR, EWR, surface
roughness
MRR, EWR, surface
roughness
EWR, MRR
Response surface methodology
(RSM), gray relational analysis
(GRA) and principal component
analysis (PCA) used for optimizing
the electrical discharge machining
responses [7].
Adaptive nero-fuzzy inference system
(ANFIS), genetic expression
programming (GEP) and artificial
neural networks (ANN) in the
prediction of EDM performance
parameters [8].
The back propagation neural
network/GA gives better prediction
results in the experimental runs than
regression models based on the RSM
method [9].
A modified PCA-based utility theory
(UT) approach for optimization of
correlated responses [10].

Atefi et al. Pulse current, pulse voltage,
(2012) pulse on-time, pulse off-time
Bharti et al. Shape factor, pulse-on time,
(2012) discharge current, duty cycle,
gap voltage, flushing
pressure, tool electrode lift
time
Surface roughness
MRR, surface finish
A hybrid model, combination of
statistical analysis and ANN, is
designed to reduce the error in
optimization of complex and non-
linear problems [11].
The average percentage difference
between experimental and ANN’s
predicted value is 4 and 4.67 for MRR
and SR respectively [12].

EXPERIMENTAL PROCEDURE sparks between a work and tool electrode

Electro discharge machining (EDM) is a immersed in a liquid dielectric medium
thermoelectric process that removes material (Figure 1).
from the work piece by a series of discrete

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Trends in Opto Electro & Optical Communications
Volume 6, Issue 3
ISSN: 2231-0401(online), ISSN: 2347-9957(print)

Fig. 1: Electrical Discharge Machine.

METHODOLOGY matrix:
Principle Component Analysis  x11 x1n 
At first, this method has been connected to  
evaluate and distinguish marvels in sociologies X  
x xmn 
in which it was hard to straightforwardly  m1
gauge the wonderful changes. PCA is valuable
in diminishment of information and Step 4: Evaluate the correlation coefficient
understanding of multi-target sets of array by using Eq. (2)
information. As of now, PCA is finding wide
COV [x I (j), x i (l)]
applications in different logical fields. The R jl  , j=1, 2, ……., n, ;
objective of PCA is, along these lines, to  xi (j) X  xi (l)
protect however much data contained in the l=1,2,…….n (2)
information as could be expected. The ideal Where, COV [x I (j), x i (l)]: the covariance of
number of chief parts (PCs) expected to
accomplish this errand is not known from the sequences xi (j) and xi (l);  xi (j) : the standard
earlier. The assignment is to locate an deviation of sequence:
arrangement of chief parts with eigen values xi (j);  xi (l) : The standard deviation of
(Table 4) that have a fundamentally bigger
esteem than the rest of the segments, the sequence xi (l) .
algorithm of principal components analysis is
given below: Step 5: Calculate the eigen values and eigen
Step 1: Convert the experimental data in to vectors by using Eq. (3)
signal to-noise ratio by using Eq. (1): (R  k lm ) Vik  0 (3)
1 n 2
 ij  10 log(  yij )
n j 1
(1) Step 6: Obtain the principal components by
using Eq. (4)
m
Pik   xi (j) XV jk
Step 2: Normalize the signal-to-noise ratio: j 1
Higher is better (4)
xi(o) (j)  minxi(o) (j) Step 7: Calculate the Total Principal
xi* (j)  Component Index (TPCI) by using Eq. (5)
max xi(o) (j)  minx i(o) (j) m

Lower is better
Pi  p
k 1
ik Xe(k) (5)

max xi(o) (j)  x i(o) (j) eig (k)

xi* (j)  Where, e(k)  m ,
max xi(o) (j)  minx i(o) (j)
 eig (k)
k 1
Step 3: Represent the multi-responses by

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Multi-variable Analysis and Optimization of EDM Process Singh et al.

eig (k)  k th eigenvalue the network. Training of an ANN plays a

Step 8: Generate response table and select the significant role in designing the direct ANN-
optimum levels of process parameters based prediction.
(Table 2):
The comparison between the experimental
Table 2: EDM Process Parameters. result and the predicted result based on PCA
Control Levels (Table 3) and ANN of full factorial data is
Factor shown in Figure 2.
1 2 3
Voltage 40 V 50 V 60 V
Current 8A 12 A 16 A
Pulse on time 6 µs 7 µs 8 µs
Pulse off time 4 µs 5 µs 6 µs
Flushing 1.5 kg/cm2 2.5 kg/cm2 3.5 kg/cm2
Pressure

Step 9: Calculate the combined objective

function (COF) by using Eq. (6):
Weighted normalized value for each response
=WiX

Fig. 2: Variation of PCA (COF) and ANN

Wi=Weightage assigned to the quality
(COF) of Testing Data w.r.t. Exemplar.
characteristic (6)
I=1, 2, 3, ………..n; and n is the number of
quality characteristics RESULT AND DISCUSSION
After calculating the TPCI’s for all the
COF=∑
experimental runs, the next step is to construct
the response table. As an illustration in order
to calculate the response value using Eq. (5),
Predictions Based On Neural Network.
we get, using this method of calculation the
The ANN is an efficient quantitative tool to
remaining response values corresponding to
predict the COF. Due to presence of non-
the factors and their respective levels are
linearity in EDM process prediction of COF is
determined. The maximum value of TPCI
done using Levenberg-Marquardt training
corresponding to each factor gives the
algorithm and five numbers of hidden neurons
predicted optimum factor level. The combined
are seen to be efficient for optimal values of
objective function (COF) for all the quality
responses. ANN splits the data into training
characteristics is calculated using Eq. (6) by
and testing sets and the studies were carried
assigning the equal weights of 0.559, 0.389
out by using MATLAB simulation
and 0.123 for each quality characteristic. Comment [AG1]: Units?
environment. The network
Table 5 shows the COF values for all the
architecture/topology or features such as
experimental runs.
number of neurons and layers are very
important factors that determine the
functionality and generalization capability of

Table 3: Dataset for the PCA (The Values of Variables are Normalized).
Process Parameter Combination Normalized Response Variable
Exp.
No. Pulse on Pulse of Flushing MMR TWR ROC
Voltage Current
Time Time Pressure (mm3/min) (%) (mm)
1 –1 –1 –1 –1 –1 0.580 0.741 0.000
2 1 –1 –1 –1 –1 0.544 0.704 0.268
3 –1 1 –1 –1 –1 0.350 0.307 0.239
4 1 1 –1 –1 –1 0.245 0.283 0.445
5 –1 –1 1 –1 –1 0.411 0.590 0.414

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Trends in Opto Electro & Optical Communications
Volume 6, Issue 3
ISSN: 2231-0401(online), ISSN: 2347-9957(print)

Process Parameter Combination Normalized Response Variable

Exp.
No. Pulse on Pulse of Flushing MMR TWR ROC
Voltage Current
Time Time Pressure (mm3/min) (%) (mm)
6 1 –1 1 –1 –1 0.344 0.567 0.780
7 –1 1 1 –1 –1 0.218 0.120 0.310
8 1 1 1 –1 –1 0.183 0.105 0.351
9 –1 –1 –1 1 –1 0.366 0.456 0.670
10 1 –1 –1 1 –1 0.482 0.601 0.849
11 –1 1 –1 1 –1 0.152 0.000 0.016
12 1 1 –1 1 –1 0.192 0.034 0.064
13 –1 –1 1 1 –1 0.776 0.395 0.759
14 1 –1 1 1 –1 1.000 0.383 1.000
15 –1 1 1 1 –1 0.347 0.142 0.408
16 1 1 1 1 –1 0.411 0.013 0.276
17 –1 –1 –1 –1 1 0.623 0.436 0.623
18 1 –1 –1 –1 1 0.390 0.766 0.462
19 –1 1 –1 –1 1 0.111 0.331 0.240
20 1 1 –1 –1 1 0.019 0.226 0.282
21 –1 –1 1 –1 1 0.831 0.651 0.816
22 1 –1 1 –1 1 0.467 0.837 0.572
23 –1 1 1 –1 1 0.114 0.031 0.336
24 1 1 1 –1 1 0.165 0.043 0.087
25 –1 –1 –1 1 1 0.590 0.514 0.844
26 1 –1 –1 1 1 0.362 0.534 0.638
27 –1 1 –1 1 1 0.036 0.158 0.294
28 1 1 –1 1 1 0.000 0.415 0.253
29 –1 –1 1 1 1 0.345 0.760 0.749
30 1 –1 1 1 1 0.192 1.000 0.658
31 –1 1 1 1 1 0.163 0.558 0.287
32 1 1 1 1 1 0.051 0.047 0.227

Table 4: Eigen Values and Eigen Vectors.

MRR (PC1) TWR (PC2) SR (PC3)
Eigen Values 1.9948 0.3497 0.8655
Eigen Vectors 0.790755 –0.178451 –0.557280
0.381559 –0.403633 0.138860
0.459283 0.917813 0.235588

Table 5: Principal Components and COF for the Experimental Runs.

Principal Components Weighted Normalized
Exp. No. TPCI COF
PC1 PC2 PC3 MRR TWR ROC
1 0.136 –0.035 0.930 0.287 0.817 0.890 0.334 2.042
2 –0.077 0.133 0.916 0.231 0.858 0.610 0.346 1.815
3 –0.059 0.201 0.479 0.149 1.121 0.635 0.540 2.297
4 –0.271 0.284 0.428 0.061 1.297 0.475 0.547 2.318
5 –0.234 0.206 0.768 0.141 1.030 0.496 0.436 1.963
6 –0.545 0.412 0.761 0.052 1.126 0.297 0.444 1.867
7 –0.139 0.264 0.262 0.075 1.344 0.575 0.617 2.537
8 –0.186 0.277 0.235 0.050 1.411 0.542 0.624 2.578
9 –0.418 0.411 0.668 0.088 1.097 0.346 0.482 1.926
10 –0.425 0.520 0.876 0.121 0.935 0.269 0.433 1.637
11 0.077 0.098 0.087 0.085 1.473 0.882 0.674 3.030
12 0.055 0.135 0.143 0.100 1.394 0.812 0.673 2.880
13 –0.226 0.737 0.859 0.318 0.623 0.305 0.504 1.434

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Multi-variable Analysis and Optimization of EDM Process Singh et al.

Principal Components Weighted Normalized

Exp. No. TPCI COF
PC1 PC2 PC3 MRR TWR ROC
14 –0.273 1.027 1.008 0.415 0.459 0.218 0.508 1.185
15 –0.143 0.390 0.365 0.134 1.126 0.500 0.607 2.234
16 0.030 0.408 0.277 0.199 1.026 0.603 0.668 2.298
17 –0.225 0.540 0.789 0.245 0.766 0.370 0.489 1.626
18 –0.332 0.136 0.907 0.110 1.043 0.464 0.383 1.891
19 –0.208 0.051 0.365 0.008 1.558 0.634 0.528 2.722
20 –0.265 0.077 0.233 0.043 1.785 0.598 0.571 2.954
21 –0.308 0.676 1.107 0.324 0.576 0.282 0.417 1.276
22 –0.390 0.215 1.023 0.135 0.951 0.398 0.363 1.713
23 –0.195 0.265 0.134 0.017 1.544 0.554 0.659 2.753
24 0.019 0.129 0.139 0.080 1.423 0.787 0.653 2.865
25 –0.333 0.623 0.864 0.190 0.802 0.271 0.461 1.535
26 –0.417 0.349 0.725 0.085 1.098 0.362 0.455 1.915
27 –0.245 0.129 0.189 0.030 1.727 0.587 0.600 2.915
28 –0.207 –0.047 0.373 0.063 1.816 0.622 0.496 2.935
29 –0.475 0.296 0.916 0.044 1.129 0.309 0.385 1.824
30 –0.363 0.028 1.014 0.047 1.394 0.352 0.323 2.069
31 –0.276 –0.002 0.586 0.017 1.450 0.594 0.447 2.492
32 –0.154 0.151 0.097 0.005 1.690 0.647 0.652 2.990

CONCLUSION fit to the model. The proposed model can

 DOE approach along with PCA and ANN
is an efficient way to find out the
optimality condition with multiple
responses and its predicted value.
 Application of PCA has been
recommended to eliminate response
correlation by converting correlated
responses into uncorrelated quality indices
called principal components which have
been as treated as independent response
variables for optimization. The approach
can be recommended for continuous
quality improvement and off-line quality
control of a process/product.
 The optimal cutting parameters are found
to be voltage of 50 V, discharge current
12 A, pulse on time 8 µs, pulse off time
4 µs and flushing pressure 1.5 kg/cm2
respectively for multi-objective
optimization in this work.
 An ANN model predicted the combined
objective function (COF) as a function of
machining parameters. The model has
been proved to be successful in terms of
agreement with experimental results as the
relative errors are very less. From the
relative error plots it is found that points
are randomly and dispersly distributed and
hence the data predicted are significantly
be used in optimization of machining
process for efficient and economic
production by forecasting the responses in
EDM operations.
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Cite this Article
Kaushal Pratap Singh, Brij Kishor
Singh, Manoj Kumar Gaur. Multi-
variable Analysis and Optimization of
Electrical Discharge Machining Process
Using a PCA-ANN Based Approach.
Trends in Opto-Electro & Optical
Communication. 2016; 3(3):
Page 7