Multi-objective optimisation of high-speed electrical discharge machining process using a Taguchi fuzzy-based approach

The paper describes the application of the fuzzy logic analysis coupled with Taguchi methods to optimise the precision and accuracy of the high-speed electrical discharge machining (EDM) process. A fuzzy logic system is used to investigate relationships between the machining precision and accuracy for determining the efficiency of each parameter design of the Taguchi dynamic experiments. From the fuzzy inference process, the optimal process conditions for the high-speed EDM process can be easily determined as A₁B₁C₃D₁E₃F₃ G₁H₃. In addition, the analysis of variance (ANOVA) is also employed to identify factor B (pulse time), C (duty cycle), and D (peak value of discharge current) as the most important parameters, which account for about 81.5% of the variance. The factors E (powder concentration) and H (powder size) are found to have relatively weaker impacts on the process design of the high-speed EDM. Furthermore, a confirmation experiment of the optimal process shows that the targeted multiple performance characteristics are significantly improved to achieve more desirable levels.