World Journal of Engineering

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Machining of Ti-6Al-4V biomedical alloy by WEDM:

Investigation and optimization of MRR and Rz using Grey-
Harmony search
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Journal: World Journal of Engineering

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Manuscript ID WJE-05-2021-0278

Manuscript Type: Research Paper

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Keywords: Harmony Search, Grey Grade, Taguchi Method, Ti-6Al-4V, WEDM

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Page 1 of 23 World Journal of Engineering

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4 Machining of Ti-6Al-4V biomedical alloy by WEDM: Investigation
5 and optimization of MRR and Rz using Grey-Harmony search
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Abstract
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10 Purpose: The objective of present research is to investigate the optimized setting of wire-cut
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electrical discharge machining (WEDM) parameters at which material removal rate (MRR) and
12 mean roughness depth (Rz) set a compromise. The machining was done on Ti-6Al-4V
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biomedical alloy. Ti-6Al-4V alloy have number of applications in engineering and medical
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15 industries due to its high strength biocompatibility. Due to high strength of Ti-6Al-4V alloys,
16 these were machined by wire electric discharge machining.
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Design/methodology/approach: The effect of control factors (i.e. pulse on-time: Pon; pulse off-
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19 time: Poff; servo voltage: SV) on the material removal rate (MRR) and mean roughness depth
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20 (Rz) is investigated in present research. The percentage influence of each factor on responses are
21 also evaluated. The multi-objective optimization is done using Grey approach initially. After that
22 the results were also calculated using Harmony search (HS). Therefore, hybrid approach of Grey
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23 and harmony search (HS) is used to find the optimized values of MRR and Rz.
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25 Findings: The maximum value of grade calculated by grey-HS is 0.7879, while in case of
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26 experimental run the maximum value of grey grade is 0.7239. The optimized setting after
27 improvisation at this grade value is Pon: 54/6 * Poff: 45 6 and SV: 70V for MRR and Rz
28 collectively. The validation of suggested setting is completed by experimentation. The values of
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MRR and Rz are comes out to be 6.4mm3/min and 54"1$6 ' which represents improvised results
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31 after the implementation of HS algorithm.
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33 Originality: The integration of Grey approach with harmony search principle in manufacturing
34 domain is yet to be explored. Therefore, in this research this is implemented in manufacturing
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35 field having applications in medical industries.

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38 Keywords: Harmony Search: Grey grade: Taguchi Method: Ti-6Al-4V: WEDM.
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41 Introduction
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43 Ti-6Al-4V biomedical alloys are utilized at several places in medical and engineering
44 fields due to exclusive properties of high corrosion resistance, good biocompatibility, better
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mechanical characteristics etc. The applications of surface treated Ti-6Al-4V was found in bone-
46 anchoring parts of joint prostheses. The problem associated with the development of the product
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by Ti-6Al-4V is their non-ductile nature. Moreover, the processing of Ti-6Al-4V by
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49 conventional machining methods leads to difficulties as a cutting-edge failure, rough surface
50 quality, high cutting forces, etc. Thus, non-conventional machining methods are considered as a
51 better option to process Ti-6Al-4V biomedical alloy. Out of all available techniques, spark
52 erosion machining is the one that is used to process difficult to cut, hard, and conductive
53 materials with sufficient accuracy and quality (Alias et al., 2012).
54 WEDM is a spark erosion machining method in which the material removal mechanism is
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the development of discrete spark between the wire electrode and workpiece. The moving wire
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 World Journal of Engineering Page 2 of 23

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3 supported by an appropriate weight is used as an electrode. Brass, copper or molybdenum wires
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of 0.05mm to 0.3 mm diameter are used as an electrode in WEDM. A gap (0.025mm to 0.05mm)
6 between electrode and workpiece is retained using an in-built microprocessor. The whole
7 machining process takes place in the presence of deionized water to remove debris (Jain et al.,
8 2004).
9 This machining process successfully implements a complex and miniature profile on hard
10 materials, which can be difficult to grab by conventional machining methods. Klocke et al.
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(2011) compared machining of titanium alloy with standard process and WEDM. The machining
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indicators are optimized for considering surface quality as response, and SEM investigates the
surface morphology. Shandilya et al. (2012) machined Al6061/SiCp composite by WEDM to
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15 optimize input parameters. It was found that Pon and Poff are inessential while SV and wire feed
16 are more influential for kerf values. Alias et al. (2012) investigated the influence of machining
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17 indicators on the responses for WEDM. The material used for the research was titanium alloy,
18 and the outcomes are MRR and SR. Kumar et al. (2018) investigated the effect of process
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parameters on SR of the machined surface. The experiments were planned and analyzed by
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21 response surface methodology. The usage of genetic algorithm makes optimization.
22 Kibria et al. (2010) worked on titanium alloy while machining these alloys on micro-EDM
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23 (powder mixed). The significantly improved response parameters like tool wear rate, surface
24 quality and MRR were after adding the powder particle in micro-EDM. Lin et al. (2000)
25 investigated the effect of ultrasonic vibrations on response variables while machining titanium
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26 alloys by EDM. It was found that higher MRR is observed in the case of ultrasonic assisted
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EDM. Li et al. (2009) worked on micro-EDM to drill deep holes on titanium alloys by changing
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29 polarity. After changing the polarity from negative to positive the value of the tool wear reduces
30 and MRR amplifies.
31 The research carried by Abbas et al. (2019) on Ti-6Al-4V, developed a relation between
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32 cutting speed, feed, depth of cut and cutting length as input parameters and SR and MRR as
33 responses. The designed arrays and empirical models were developed using full-factorial and
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regression analysis. The research conducted by Sharma et al. (2020) optimized the parameters of
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micro-EDM drilling to drill quality microholes using a hybrid approach of optimization. Another
37 research was done by Kumar et al. (2019) on biomedical titanium alloy developing micro-holes
38 by the micro-EDM drilling process. The experiments were planned using the Taguchi method
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39 and the responses were optimized using the non-dominated sorting genetic algorithm-II (NSGA-
40 II). The confirmation experiments were performed, and a close relationship observed between
41 predicted optimal solutions and experimental results.
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In recent years, numerous researchers (Statistical optimization) worked on multi criteria

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44 decision making (MCDM) approach to investigate and solve the manufacturing related issues,
45 where more than one response characteristics (responses are contradictory) were involved. Gupta
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46 et al. (2020) optimized the process parameters of micro ultrasonic machining using NSGA-II,
47 while developing micro-channels. Zarei et al. (2009) used harmony search for the optimization
48 of multi-pass face milling. Researchers have successfully optimized the number of passes, depth
49 of cut, speed and feed for the economic machining using harmony search.
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It needs much effort to discover the response characteristics of a manufacturing process; through
52 conventional techniques due to their instability, uncertainty and complex mechanism. Therefore,
53 non-traditional optimization methods like genetic algorithm, NSGA-II, artificial neural network,
54 etc. are used to predict the response characteristics in complex manufacturing processes. Saka
55 (2009) used the HS algorithm to categorize steel section designations from the available steel
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3 table. Maheri and Narimani (2014) implemented HS to find out the local optima efficiently. It
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was used to reduce the weight on the steel frame, including the two-bay, three store planer frame.
6 In another problem of the implementation of HS in manufacturing processes. Bekdas and
7 Nigedeli (2011) investigated the optimal set of parameters in tuned mass dampers. With the
8 combination of sensitivity analysis, the HS algorithm was successfully implemented to predict
9 the optimal design of shell and heat exchangers (Fesanghary et al., 2009). Out of all available
10 techniques, HS get preferred due to its fast and reliable response. Also, due to the music
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improvisation, a harmony has been set between the input and output variables that increase the
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balance and hence the accuracy.
After reviewing the literature, it is evident that the machining of Ti-6Al-4V by traditional
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15 means produces several problems like tool wear, rough surface, etc. Therefore, non-traditional
16 way of machining is adopted for the processing of Ti-alloys. The WEDM is one of the viable
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17 options to machine Ti-6Al-4V alloy precisely up to the required quality. Moreover, limited
18 research (Devarasiddappa et al., 2020) has been published on the optimization of control
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factors using the hybrid approach of optimization while machining Ti-6Al-4V biomedical alloy.
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21 The design of the experiment is used for its planning and the Taguchi method for single response
22 optimization. The Grey approach implement for the calculation of grey grades, which are further
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23 modeled by regression analysis. The HS algorithm solves the empirical model. Therefore, the
24 optimization of control factors uses hybrid approach of Grey-HS due to the accuracy and fast
25 response of the HS algorithm. The confirmation experiments are performed to verify the validity
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26 of results obtained after implementing Grey-HS approach of optimization.

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2. Experimental Details
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2.1 Work Material and Experimental Set-up
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33 The work-material in the present work is Ti-6Al-4V biomedical material with a rectangular size
34 of 300mm×25mm×25mm. The specimen extracted from this is a size of 10mm×10mm×25mm.
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35 That material was machined by a wire cut electrical discharge machine (Electronica, Pune,
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India). A brass wire of 37/6 is used as an electrode to machine the material. The deionized
38 water was applied to flush away the debris induced by the machining of the material. The
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39 process parameters are adopted after conducting some preliminary experiments. The working
40 levels of process parameters and their unit are depicted in Table 1. During the research work,
41 some of the parameters are kept constant. The values of fixed control factors are given in Table
42 1.
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Table 1. Variable and fixed control factors, their units and levels
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S. No. Control factors Units Levels
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50 1 Pulse on- time (Pon) µs 120 125 130
51 2 Pulse off- time (Poff) µs 45 50 55
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53 3 Servo Voltage (SV) V 60 65 70
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55 Fixed Control factors
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 World Journal of Engineering Page 4 of 23

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3 Machining parameters Units Fixed values
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5 1 Work material - Ti-6Al-4V
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2 Wire material - brass (dia. 0.25mm)
8 3 Work material size mm (300×25×25)
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10 4 Specimen Size mm (10×10×25)
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5 Dielectric fluid - de-ionized water
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13 6 Conductivity of Siemens per 20
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15 7 Peak Current machine control 12
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8 Wire feed m/min 4
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21 2.3 Measurement of Response Variables
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23 Eq. 1 is used to calculate the MRR in terms of mm3/min. In Eq. 1, the cutting speed is recorded
24 from the machine tool display in mm/min. However, for the measurement of kerf width, the wire
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26 is entered into the material at the given process parameter setting (at which the kerf width to be
27 measured) given in the trial run and moved back to the initial position. The entrance of the wire
28 forms the slot, which is measured using profile projector (Mitutoyo make profile projector PJ-
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30 3000 model) in mm. The profile projector used to measure the kerf width in the present work is
31 shown in Fig. 1.
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33 3
34 =( × × ) (1)
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36 The SURFTEST (model: SJ-301P, Mitutoyo make) surface roughness tester measures the mean
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38 roughness depth (Rz). It is the average value of five maximum peaks to five lowest valleys. The
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39 least count of roughness tester is /"//56 " The machined surface was cleaned by acetone to
40 remove any dust particles, and after that, the Rz is measured perpendicular to the wire movement
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direction. Three reading were taken on a surface and the mean value of Rz is selected for analysis
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43 purposes. Here, Rz get chosen over average surface roughness (Ra) due to more accurate and
44 reliable results. The Ra gives the average roughness that will sometimes provide a mean value,
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whether the peak and valley of roughness are at maximum height. LEO0435VP completes the
47 scanning electron microscopy (SEM) by to investigate the morphology of the machined surface
48 of biomedical material.
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24 Fig. 1 Profile Projector used for the measurement of Kerf width
25 3. Methodology adopted in Present work
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28 The optimization process selected in current research is the hybrid approach of Grey-Harmony
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29 search, and the below paragraphs describe this.

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3.1 Experimental Planning using Taguchi Method
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34 Taguchi method (Roy, 1990) is a problem solver tool that develops an experimental array as per
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35 the number of input parameters. For single response optimization also, the Taguchi method is
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implemented as well. In current work, there is the usage of three machining indicators (namely
38 Pon, Poff and SV). The analysis of variance (ANOVA) identifies the percentage influence of each
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39 machining indicator for the respective response.

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42 3.2 Grey Relational theory
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43 The Taguchi method designed the experimental array, after which the same strategy
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analyzes a single response. But as the number of responses increases, the integration of some
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46 other technique is required. In the present research, the Grey approach is used, which is a
47 mathematical approach used for multiple performance characteristics optimization. In this
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approach, all the mean values of responses are processed as per the grey method’s procedure.
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50 The steps of grey relation are (i) Normalization (ii) deviational sequence (iii) calculation of grey
51 coefficient (iv) grey grade calculation. This approach is proposed by Deng (1982), which
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describes that the mean value of responses or signal to noise (S/N) ratio is processed to obtained
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54 grade values (Jangra et al., 2016). The procedure for the implementation of Grey relational
55 analysis is given in appendix A1.
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3.3 Harmony Search (HS)
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7 Recently, one metaheuristic algorithm was proposed by Geem et al. (2012) for practical
8 optimization. The algorithm consists of three rules namely random selecting (RS), harmony
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memory considering (HMC) and pitch adjusting (PA). Using these rules, musicians improvise
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11 and a perfect state of harmony. Musician uses three rules for improvisation: (1) paly the note
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12 from memory (2) paly the note from the previous selected note (3) select the random note.
13 There are two components in the algorithm like exploration and exploitation. Exploration
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14 means search the solution globally, while exploitation means searching solution locally. With the
15 combination of three rules (RS, HMC and PA) and two components, the algorithm concentrates
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the search towards good solution and also increase the convergence rate. RS rule works on global
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18 optima and it tries to find the solution in early iteration. It also prevents the algorithm to stuck on
19 the local optima. PA rules works for a better search in local optima and gives the better results.
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20 Therefore, the better results can easily be obtained using harmony search using RS, HMC and
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The evaluation of grey grade in the previous step, is processed by regression analysis to develop
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24 an empirical model. This model is analyzed and processed by HS. This meta-heuristic approach
25 of optimization is a comparatively newer algorithm, which simulates the process of music
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26 improvisation. While music improvisation, every performer enhances its pitch to get a better
27 harmony within the range again and again. Fig. 2 shows all the particulars of the music
28 improvisation process.
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Page 7 of 23 World Journal of Engineering

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4 First step: Initialization of
Second step: Initialization
5 Optimization problem and
of Harmony memory
6 HS algorithm parameters
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10 Third step: Improvisation
Memory, pitch adjusting
11 of new harmony from
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rate, random choosing
12 harmony memory matrix
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16 Yes New
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23 Termination
Yes
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Fig. 2 Optimization method in HS algorithm
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32 The optimization process uses HS algorithm shown in Fig. 2 and is described below (Geem,
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34 First Step: The optimization problem and parameters of the algorithm (HS) initialize as per the
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35 below-mentioned objective function.

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minimize = objective function (Y)
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38 where, Y= f(X)
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39 and X is the input process parameters. Here, these are Pon, Poff and SV.
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42 Second step: Start the harmony memory (HM), which is an essential part of the search algorithm.
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43 The solution is investigated from the search space to find out the feasible solution.
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Third step: Improvisation of new harmony, the development of a novel harmony is called
46 improvisation.
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Forth step: Upgradation of HM, it is done by finding out the new harmony and comparing it with
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49 the existing one. Both values are investigated using an objective function. Out of those, better
50 harmony keeps for analysis and the worst harmony excludes from the analysis.
51 Fifth step: The stopping criterion is checked and if it is satisfied with the improvisation, only, in
52 that case, the search (iterative) is stopped. Otherwise, the third and fourth steps gets repeated.
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 World Journal of Engineering Page 8 of 23

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3 4.Results and Discussions
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5 Table 2 gives the values of responses (MRR and Rz) corresponding to the L9 OA. The effect
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7 of each control factor on the responses are evaluated using analysis of variance (ANOVA). This
8 section subdivides itself two parts, where one part dedicates to single response optimization;
9 however, the second part dedicates to multiple performance optimizations using the hybrid
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13 Table 2. Experimental array using L9 OA and corresponding result
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15 Sr. Control Factors Response 1 [MRR (mm3/min)] Response 2 [Rz 6 N
16 No. Pon Poff SV MRR1 MRR2 MRR3 Mean Rz1 Rz2 Rz3 Mean
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1 130 45 60 6.76 6.89 6.9 6.85 16.873 17.541 17.954 17.456
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19 2 130 50 65 4.39 4.51 4.45 4.45 14.629 14.247 14.264 14.38
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20 3 130 55 70 2.14 2.11 2.2 2.15 15.326 15.125 15.008 15.153
21 4 125 45 65 6.7 15.66
7.2 6.9 6 15.683 15.634 15.663
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23 5 125 50 70 3.12 3.15 3.18 3.15 14.923 14.819 14.658 14.8

24 6 125 55 60 1.52 1.57 1.56 1.55 16.894 16.772 16.824 16.83
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7 120 45 70 5.07 5.02 5.06 5.05 14.821 14.629 14.659 14.703

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8 120 50 60 2.4 2.2 2.6 2.4 15.429 15.611 14.389 15.143
28 9 120 55 65 1.5 1.3 2 1.6 13.994 13.886 13.769 13.883
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4.1 Analysis of MRR and Rz using ANOVA
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34 In the present work, the Ti-6Al-4V is machined. ANOVA investigates the influence of
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35 Pon, Poff and SV on MRR and Rz. Table 3 depicts the ANOVA for the mean values of MRR and
36 Rz. It is clear from Table 3 that Poff has an 87.40% contribution in the calculations of MRR
37 preceded by Pon (9.31%) and SV (3.17%). Similarly, for the investigation of Rz, Pon (24.48%)
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and Poff (19.28%) trails the contribution of SV (56.14%). Table 3 reveals that the probability-
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values (P-values) of all the control factors are less than 0.05. It clarifies that all the control
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41 factors significantly influence the investigation of response variables at a 95% confidence
42 interval (Sharma et al., 2021). Fig. A1 shows the probability plot for MRR and Rz; it signifies
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43 that all the values are found within the range. The R2 and R2 (adj.) are also found in close
44 relation to MRR and Rz. The values in both cases are greater than 99%. The experimental design
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predicts the future outcomes of MRR and Rz in the machining of Ti-6Al-4V biomedical alloy by
46 WEDM.
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Table 4 at different levels gives the response values of MRR and Rz of Pon, Poff and SV.
49 Fig. 3 represents a variation of the response variable with the control factors. It is clear from Fig.
50 3a that Pon positively affects MRR, while Poff negatively influence MRR (Fig. 3b).
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5 Table 3: ANOVA for MRR and Rz
6 Source DF MRR Rz
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8 SS %p MS F P SS %p MS F P
9 Pon 2 3.2317 9.31 1.6158 62.55 0.016 2.5990 24.48 1.2995 269.28 0.004
10 Poff 2 30.3267 87.40 15.1633 586.97 0.002 2.0471 19.28 1.0235 212.10 0.005
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12 SV 2 1.0850 3.17 0.5425 21.00 0.045 5.9607 56.14 2.9803 617.57 0.002
13 Residual 2 0.0517 0.14 0.0258 0.0097 0.09 0.0048
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16 Total 8 34.6950 100 R2: 99.85%; R2 10.6164 100 R2: 99.91%; R2
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17 (adj.):99.40% (adj.):99.64%
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20 Table 4. Response Table for MRR and Rz
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22 Level MRR Rz
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25 1 3.017 6.200 3.600 14.58 15.94 16.48
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2 3.800 3.333 4.250 15.76 14.77 14.64
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28 3 4.483 1.767 3.450 15.66 15.29 14.89
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30 Delta 1.467 4.433 0.800 1.19 1.17 1.84
31 Rank 2 1 3 2 3 1
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34 The maximum Pon level 54/6 and the lowest Poff level (45 6 favors the highest value
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35 of MRR. At the high value of Pon, the current on-time in the circuit increases, which increases the
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discharge energy (spark energy) in the circuit. This large amount of discharge energy causes
38 higher material removal from the surface and increases the MRR. The low value of Poff decreases
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39 the current off-time in the circuit, which increases the discharge energy in the gap. The same
40 process repeated, which increases the MRR. Fig. 3c reveals the SV’s effect on MRR, the
41 maximum MRR (4.25mm3/min) at a medium value of SV (65V). After that increasing SV value
42 from 65V to 70V, the value of MRR got observed to reduce up to 3.45mm3/min. The mechanism
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behind this reduction is the spark waiting time. With the increase in SV value the spark waiting
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time increases, which decreases discharge energy in the circuit and finally MRR. Fig. 3d, Fig.
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46 3e, and Fig. 3f envisaged the effect of Pon, Poff, and SV on Rz. At the minimum value of Pon (120
47 6 ' the medium value of Poff 7/6 and medium value of SV (65V) corresponds to the minimum
48 value of Rz. It has been observed that Rz is related to maximum peak and minimum valley on the
49 surface. The discharge energy generated due to the control factor’s setting removes the material
50 into craters and debris. These craters are observed as the prime reason for surface quality values.
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Larger Pon and smaller Poff increases the crater size from the machined surface, which increases
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53 the Rz value. Thus, removing large size craters, the Rz value ameliorates. The scatter plots for
54 MRR (Fig. A2) and Rz (Fig. A3) in the Appendix provides better understanding of variations.
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3 It became necessary to envisage the results responses at 95% after the ANOVA and
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5 variation of MRR and Rz with the control factors. After adopting the procedure, as mentioned by
6 Roy (2001), the range of confirmation experiments (CE) at a 95% confidence interval is
7 evaluated. Also, the CE is performed for single performance characteristics suggested by
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9 ANOVA. Table 5 shows the optimized setting for MRR and Rz. The experiments are conducted
10 on the optimized parametric setting and found that the resultant value is between the confidence
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interval (CI).
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MRR
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MRR (mm3/min)

MRR (mm3/min)
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115 120 125 130 135
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Pon (us) Poff (us)

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MRR
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Rz
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MRR (mm3/min)

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SV (V) 116 118 120 122 124 126 128 130 132 134
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(c) SV versus MRR (d) Pon versus Rz
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(e) Poff versus Rz (f) SV versus Rz
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22 Table 5. CICE results of single optimization at optimum setting
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Predicted Actual Value
Responses Optimum Envisaged CI at 95% Confidence
25 Optimal
Parameters Level
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26 Value
27 MRR (mm3/min) (Pon)3(Poff)1(SV)2 7.3996 CICE: 6.86745 < µMRR < 7.93178 7.62
28
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29 Rz (µm) (Pon)1(Poff)2(SV)2 13.3212 CICE: 13.091 < µRz < 13.5514 13.44
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31
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33 4.2 Multi-Response Optimization using Grey-HS
34 Taguchi is used for single response optimization. But for multiple performance
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35
36 characteristic optimization, the grey approach is used along with HS, as explained in Section 3.
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40 4.2.1 Grey Approach
41
42 In the multiple performance characteristics optimization by the Grey approach, the first step is
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43
44
normalization. It is required to converge the range of scattered values. Depending upon the
45 nature of responses, either Eq. 2 or Eq. 3 is used to normalize all values. Table 6 gives the value
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46 after implementing the normalizing the value of MRR and Rz for all trial runs.
47
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49 Table 6. Normalizing, Sequencing (deviational), Grey coefficient and Grade
50 Normalization Deviational Sequence Grey Coefficient
Sr.
51 GRG
52 No. MRR Rz MRR Rz MRR Rz
53
54 1 1.0000 0.0000 0.0000 1.0000 1.0000 0.3333 0.6667
55 2 0.5472 0.8610 0.4528 0.1390 0.5248 0.7825 0.6536
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3 3 0.1132 0.6446 0.8868 0.3554 0.3605 0.5845 0.4725
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5 4 0.9717 0.5028 0.0283 0.4972 0.9464 0.5014 0.7239
6
7
5 0.3019 0.7435 0.6981 0.2565 0.4173 0.6609 0.5391
8 6 0.0000 0.1754 1.0000 0.8246 0.3333 0.3775 0.3554
9
10 7 0.6604 0.7705 0.3396 0.2295 0.5955 0.6854 0.6405
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8 0.1604 0.6474 0.8396 0.3526 0.3732 0.5864 0.4798
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13 9 0.0094 1.0000 0.9906 0.0000 0.3354 1.0000 0.6677
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16 Table 7. Response Table for Grade
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18 Level Pon Poff SV
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20 1 0.5960 0.6770 0.5006
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2 0.5395 0.5575 0.6817
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23 3 0.5976 0.4985 0.5507

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25 Delta 0.0581 0.1785 0.1811
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27 Rank 3 2 1
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29 The deviational sequence is obtained after subtracting the pre-processed value of

30
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experiments from the reference value (Eq. 4). The estimate of a deviational sequence of MRR
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32 and Rz after subtraction from the reference value. Table 6 depicts the deviational values for all
33 the trial runs. The grey coefficients and grades are evaluated using Eq. 5 and Eq. 6 respectively
34
and presented in Table 6. The methodology section explains the procedure where it evaluates
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35
36 coefficient and grade values. Table 7 shows the response table of grey grade, and Fig. 4
37 represents the variation of grade values with the process parameters.
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1.0 1.0

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0.8 0.8
0.677
9 0.596 0.5976
0.5395 0.5575
10 0.6 0.6
Grade

Grade
0.4985
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12 0.4 0.4

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14 0.2 0.2

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16 0.0 0.0
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116 118 120 122 124 126 128 130 132 134 40 42 44 46 48 50 52 54 56 58 60
17 1.0
Pon (us) Poff (us)
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20 0.6817

21 0.5507
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22 0.5006
Grade

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23 Grade
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28 0.0
56 58 60 62 64 66 68 70 72 74
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SV (V)
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33 Fig. 4 Variation of grey grade with the process parameter according to grey approach
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36 4.2.2 Regression and HS
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In the present work, after calculating the grade values, it is mandatory to convert these values in
39
40 form Equation. The regression analysis is used to evaluate grey grade as per the input parameters
41 (Eq. 2).
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44 Grey Grade= 1.12+ 0.00016×Pon-0.01785×Poff+0.00501×SV (2)
45
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46 The range of Pon, Poff and SV are described in Eq. 3, Eq. 4 and Eq. 5 respectively. During the HS,
47
48 these ranges are used as lower and upper limit for improvisation.
49 120 130 (3)
50 45 55 (4)
51
52 60 $% 70 (5)
53 The methodology adopted in current research in already explained. However, the
54 algorithm parameters used for the calculation of grade are memory size: 50; bandwidth: 0.19;
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3 pitch adjustment rate: 0.3; maximum number of iteration: 200; harmony memory considering
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5 rate: 0.95.
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7 1
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9 0.9
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Grade Values

0.6
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28 0
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0 20 40 60 80 100 120 140 160 180 200

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30 Iteration
31 Fig. 5 Grade value after harmony search iterations
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34 After using HS, the predicted grade’s value is 0.7879, and the parametric setting for this
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35 value is Pon: 54/6 * Poff: 45 6 * SV: 70V. Fig. 5 represents the variation of grade value with the
36 iteration. Increase in the number of iterations, the variation in the grade value decreases; after 11
37 iterations, it became uniform. The setting suggested by the grey approach is also Pon: 54/6 * Poff:
38
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45 6 * SV: 65V (Table 7). The confirmation experiments (Table 8) are performed on suggested
39
40
settings to find the best possible outcome. The value of responses is compared with trial run
41 number 4, because it expresses the maximum grade’s value (0.7239). Confirmation experiments
42 are conducted on the optimized setting suggested by Grey-HS, and a close agreement has been
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43 observed between the predicted values and experimental values.

44
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Table 8. Confirmation results and comparison with other trial runs

46
47 Response Trial 4 Optimized Setting (Pon)3(Poff)1(SV)3
48
49 (Pon)2(Poff)1(SV)2 Predicted Experimental
50
51 GRG 0.7239 0.7879 -
52 MRR 7.39 6.4 6.6
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54 Rz 15.92 13.84 13.721
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3 5.Surface Morphology
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5 SEM micrographs of the machined surface are analyzed and are presented in Fig. 6a to Fig.
6
7
6c. In the WEDM process, the material removal takes place with the help of discrete sparks (Ho
8 et al., 2004).
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13 microcracks
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40 Depoisted lumps
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microcracks
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Globules
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7 Globules
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9 lumps
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18 microcracks
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26 (c) (Pon)130(Poff)45(SV)70
27 Fig. 6 SEM micrograph for (a) (Pon)120(Poff)55(SV)65 (b) (Pon)130(Poff)45(SV)60 (c)
28
(Pon)130(Poff)45(SV)70
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31 The WEDM process depends upon number of process parameters, which are to be
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32 controlled for better machining rate and surface quality. In this process, better surface finish is
33 one that is free from surface defects like globules, micropores, microcrack and sub-surface
34 formation. However, these defects can only be minimized by controlling the process parameters.
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35
High value of Pon and low value of Poff increases the spark intensity, which increases the chances
36
37 of micropores, microcracks, globules and other defects (Jangra, 2014). Thus, the surface
38 morphology of the surface machined at low, high and optimized setting is investigated. The
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39 process parameters at high discharge energy (HDE) are Pon: 54/6 * Poff: 45 6 * SV: 60V, and low
40 discharge energy (LDE) are Pon: 120 6 * Poff: 55 6 * SV: 65V, while surface morphology at the
41 optimized setting is also evaluated (Fig. 6c).
42
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It is clear from Fig. 6a and Fig. 6b that the increase in discharge energy increase the globule
43
size, depoisted layers and crack formation. The main reason for the crack formation is the higher
44
45 thermal stresses than the fracture strength. This not only depends upon the process parameters of
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46 WEDM, but the material characteristics also. The subsurface cracks on the machined surface
47 reveals the amorphous nature either in compound form or free form. The reason of microcracks
48 on the machined surface is generally the frequent heating and cooling by dielectric. This frequent
49 heating and cooling (quenching) increase the yield strength, while plastic deformation of
50 material during heating and cooling develop the tensile stresses, which increases the crack
51
52
formations (Lee and Li, 2003). In WEDM, quick heating and cooling causes quenching effect
53 resulting into micro cracks in top layer of machined surface. Micro cracking is seen even at low
54 discharge energy but thickness of redeposits are low with more numbers of pores that gives low
55 value of Rz as it can be seen from Fig 6a. Also, HDE increases the crater size, which enhances
56 the material removal rate. Because of this, some of the debris stick and redeposited on the
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3 machined surface, while these material deposition and quenching is reduced after setting the
4
5
process parameters of WEDM at LDE. Fig. 6a shows little presence of microcracks, subsurface,
6 depoisted lumps and small size globules. The elimination of these surface defect is not possible
7 as some of the discharge energy is always available during machining (at any setting of process
8 parameters). According to this, LDE is beneficial to improve the surface quality and reducing the
9 surface defects (Chaudhari et al., 2020). But all the objectives like of high surface quality and
10 good material removal rate cannot achieved by LDE. This is because high Pon and low Poff
11
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develops HDE, which gives high MRR and surface roughness. To obtain better surface quality
12
13
discharge energy should be low. Thus, to cope up with the conflicting nature of response
characteristics, the optimization should be done. Therefore, at optimized setting the surface
or
14
15 defects are less than the defects observed at HDE. The optimized setting in present work is Pon:
16 130µs; Poff: 45 µs; SV:70V. From the optimized setting it is evident that discharge energy is
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17 lower than the HDE but higher than the LDE. Therefore, the microcracks, subsurface, depoisted
18 lumps at the machined surface obtained at optimized setting (Fig. 6c) are less than the surface
19
defects at machined surface obtained at HDE (Fig.6b). HDE have more volume of deposits and
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20
21 wider size of globules (Fig. 6b and 6c), that increases the difference between highest peaks and
22 lowest valleys. The more numbers of cracks with wider geometry are covered by the large size
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23 globules deposited against the higher melting of Ti alloy.

24
25
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26 6.Conclusions
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28 The influence of control factors (i.e. Pon, Poff and SV) on MRR and Rz are investigated in the
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present research. Firstly, single quality characteristic optimization is done using Taguchi and
31 then multiple characteristics optimization is taking place using the hybrid of Grey and harmonic
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32 search algorithm. The concluding remarks of the current experimentation are drawn as:
33
34
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35 1. The maximum value of MRR is found at the Pon: 130 6 * Poff: 45 6 and SV: 65V. The
36 experimental and envisaged values are found in the range of 95% CI. These values have a
37
close agreement in between the two values. Pon, Poff and SV’s percentage influence for
38
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39 the evaluation MRR is 9.31%, 87.40% and 3.17%, respectively.

40 2. The minimum Rz is presented at Pon: 120 6 * Poff: 50 6 * SV: 65V and the experimental value
41
(13.446 found to be in line with the predicted value (13.326 " Pon, Poff and SV’s influence
42
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43 is 24.48%, 19.28% and 56.14%, respectively.

44 3. The grey analysis of mean values depicts that the maximum value of grade at the trial
45
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experiment is 0.7239. The parametric setting suggested by grey grade is Pon: 54/6 * Poff:
46
47 45 6 * SV: 65V. The grey grade is also evaluated using HS to improvise the results and it
48 was found that the improved grey grade value is 0.7879 with optimized setting Pon:
49 54/6 * Poff: 45 6 * SV: 70V. The results are verified experimentally and found an
50
51 excellent result reproductivity between experimental and predicted values.
52 4. The hybrid approach (Grey-HS) of optimization is successfully implemented for the
53 optimization of machining parameters of WEDM while machining Ti-6Al-4V alloy.
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3 The hybrid approach is used to optimize MRR and Rz. The other process parameters viz.: cutting
4
5
speed, residual stresses, microhardness, corrosion rate, bioactivity, wear, and other surface
6 characteristics can be optimized by this approach for Ti-6Al-4V biomedical alloy.
7
8
9 References:
10
11 Abbas A. T., Sharma N., Anwar S., Hashmi F. H., Jamil M., and Hegab H. (2019), “Towards
W
12 Optimization of Surface Roughness and Productivity Aspects during High-Speed Machining of Ti–
13 6Al–4V”, Materials, Vol. 12 No. 22, pp 1-13.
or
14
15 Alias, B., Abdullah and Abbas, N. M. (2012), “WEDM Influence of Machine Feed Rate in Machining
16 Titanium Ti-6Al-4V using Brass Wire and Constant Current (4A)”, Procedia Eng, Vol. 41 No. 1, pp.
ld
17 1812 – 1817.
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19 Bekdas G. and Nigdeli S. M. (2011), “Estimating optimum parameters of tuned mass dampers using
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20 harmony search”, Engineering Structures, Vol. 33 No. 9, pp. 2716–2723
21
22 Chaudhari R., Vora J. J., Patel, V., López de Lacalle L. N. and Parikh, D. M. (2020) “Effect of
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23 WEDM Process Parameters on Surface Morphology of Nitinol Shape Memory Alloy,” Mater., Vol 13
24 No. 21, pp 1-14.
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26 Deng, J. (1982), Control Problems of Grey Systems, Syst. Control. Lett, Vol. 2, No, 5(1), pp 288-294.
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28 Devarasiddappa, D., Chandrasekaran, M., & Arunachalam, R. (2020). “Experimental investigation
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29 and parametric optimization for minimizing surface roughness during WEDM of Ti6Al4V alloy using
30 modified TLBO algorithm”, Journal of the Brazilian Society of Mechanical Sciences and
31 Engineering, Vol. 42 No. 3, pp 1-18.
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33 Fesanghary M., Damangir E., and Soleimani I. (2009), “Design optimization of shell and tube heat
34 exchangers using global sensitivity analysis and harmony search algorithm”, Applied Thermal
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Engineering, Vol. 29 No. 5-6, pp. 1026–1031.
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37 Geem Z. W (2012), “Effects of initial memory and identical harmony in global optimization using
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harmony search algorithm”, Appl Math Comput, Vol. 218, pp 11337- 11343.
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40 Gupta R. D., Gupta P. and Khanna R. (2020), “Parametric optimization of USM Parameters by
41 Taguchi and NSGA-II for the Development of µ-Channels on Pure Titanium”, Grey Systems: Theory
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and Application, Emerald, Vol. 10 No. 2, p 173-192.
44 Ho, K., Newman S., Rahimifard, S. and Allen, R. (2004) “State of the art in wire electrical discharge
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machining (WEDM),” Int. J. Mach. Tools Manuf. Vol. 44, pp. 1247–1259.
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47 Jain, V. K. (2004), “Advanced machining processes”, Allied Publishers.
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49 Jangra, K. K. (2014), “An experimental study for multi-pass cutting operation in wire electrical
50 discharge machining of WC-5.3% Co composite,” Int. J. Adv. Manuf. Technol. Vol. 76, pp. 971–982.
51
52 Jangra, K. K., Sharma, N., Khanna, R. and Deepak (2016), “An Experimental Investigation and
53 Optimization of Friction Stir Welding Process for AA6082 T6 (Cryogenic Treated and Untreated)
54 using an Integrated Approach of Taguchi, GRA and Entropy Method”, Proc. Inst. Mech. Eng. L, Vol.
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3 Kibria, G., Sarkar, B. R., Pradhan, B. B. and Bhattacharyya B. (2010), “Comparative Study of
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Different Dielectrics for Micro-EDM Performance during Micro Hole Machining of Ti-6Al-4V
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6 Alloy”, Int J Adv Manuf Tech, Vol. 48, pp 557-570.
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Klocke, F., Welling, D. and Dieckmann, J. (2011), “Comparison of Grinding and Wire EDM
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9 Concerning Fatigue Strength and Surface Integrity of Machined Ti-6Al-4V Components”, Procedia
10 Eng, Vol. 19 No. 1, pp 184 – 189.
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Kumar, V., Singh, V., Katyal, P. and Sharma, N. (2019), “EDM W in Ti-6Al-7Nb:
13 Experimental Investigation and Optimization using NSGA-II”, Int J Adv Manuf Tech, Springer, Vol.
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14 104 No. October, p 2727–2738.
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16 Kumar, V., Jangra, K. K., Kumar, V. and Sharma, N. (2018) “GA-based optimisation using RSM in
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17 WEDM of Nimonic-90: a nickel-based super alloy”, International Journal of Industrial and Systems
18 Engineering, Vol. 28, No. 1, pp.53–69.
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20 Lee, S. H. and Li, X. (2003), “Study of the Surface Integrity of the Machined Workpiece in the EDM
21 of Tungsten Carbide”, J. Mater. Process. Technol., Elsevier, Vol. 139 No. 1-3, pp 315-321.
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23 Li M. S., Chi G. X., Wang Z. L., Wang Y. K. and Li D. (2009), “Micro-Electrical Discharge
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25 439.
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27 Lin Y. C., Yan B. H. and Chang Y. S. (2000), “Machining Characteristics of Titanium Alloy (Ti-6Al-
28 4V) using a Combination Process of EDM with USM”, J Mater Process Technol, Vol. 104 No. 3, pp
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31 Maheri, M. R., and Narimani, M. M. (2014), “An enhanced harmony search algorithm for optimum
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32 design of side sway steel frames”, Computers and Structures, Vol. 136, pp. 78–89.
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34 Roy, R. K. (1990), “A Primer on Taguchi Method”, Van Nostrand Reinhold”, New York.
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36 Saka M. K. (2009), “Optimum design of steel skeleton structures in Music-Inspired Harmony Search
37 Algorithm”, Z. W. Geem, Ed., Springer, Berlin, Germany.
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39 Shandilya, P., Jain, P. K. and Jain, N. K. (2012), “Parametric Optimization during Wire Electrical
40 Discharge Machining using Response Surface Methodology”, Procedia Eng, Vol. 38 No. 1, pp 2371
41 – 2377.
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43 Sharma, N., Ahuja, N., Goyal, R. and Rohilla, V. (2020), “Parametric Optimization of EDD using
44 RSM-Grey-TLBO-based MCDM Approach for Commercially Pure Titanium”, Grey Systems: Theory
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and Application, Vol 10 No. 2, pp 231-245.

46
47 Sharma, R.C., Dabra, V., Singh, G., Kumar, R., Singh, R.P. and Sharma, S. (2021), "Multi-response
48 optimization while machining of stainless steel 316L using intelligent approach of grey theory and
49 grey-TLBO", World Journal of Engineering. https://doi.org/10.1108/WJE-06-2020-0226
50
51 Zarei O., Fesanghary M., Farshi B., Jalili Saffar R., and Razfar M. R. (2009), “Optimization of multi-
52 pass face-milling via harmony search algorithm”, Journal of Materials Processing Technology, Vol.
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Appendix
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6 A1. Equations and Procedures for the implementation of Grey Relational Analysis
7
8 Normalization (or Data pre-processing)
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10 It is evident from the results obtained that sometimes the value of response is in thousands and
11
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sometimes in decimal form. Thus, a procedure is required to transform these values in some
12
13 normalized value. Consequently, the estimate of responses is transformed into a dimensionless
number using Eq. A1 and A2. As per the nature of response characteristics, the normalization
or
14
15 equations are categorized for ‘larger the best’ and ‘smaller the best’ quality features. In the
16 present research, Eq. A1 is for ‘larger the best’ type and Eq. A2 is for ‘smaller the best’ type
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17 quality features.
18
19 βi(m) ― min βi(m)
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20 βi ∗ (m) = (A1)
21 maxβi(m) ― min βi(m)
22
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23 𝑚𝑎𝑥βi(m) ― βi(m)
24 βi ∗ (m) = (A2)
25 maxβi(m) ― min βi(m)
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27 Where, β*i(m) – Sequence obtained after normalizing the responses,
28 β i(m) – Raw data value corresponding to the trial run,
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Where m=1 and 2 are for first and second response respectively.
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31 i=1, 2, 3…, n for trial run from 1 to n.
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Evaluation of grade values
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36 Once normalization is completed, the deviational values are evaluated using Eq. A3. In
37 this, one reference value is selected which is equal to one and the normalized value
38 corresponding to the trial run is subtracted. Furthermore, every normalized value obtained after
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39 either from Eq. A1 or Eq. A2 is processed to obtain deviational value (∀).

40
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∀0i(m) = ⃒β0 ∗ (m) ― βi ∗ (m) ⃒ (A3)
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44 In the next step, coefficients of grey approach (ϑ) are evaluated using Eq. A4. For the
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evaluation of coefficient (ϑ), the other parameters like deviation value (∀) and identification
46 coefficient (ζ) are used. The value of ‘ζ’ is usually considered as 0.5 for giving equal preferences
47
to all the response variables. In present work, the value of ‘ζ’ is taken as 0.5 to give equal
48
49 importance to each response. After evaluating ‘ϑ′ for each trial run, the next step is to evaluate
50 grey grade (𝜔). The value of ‘𝜔’ is computed by averaging all the values of ‘ϑ′. The value of
51 grade is predicted using Eq. A5.
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53 ∀min + ζ.∀max
54 ϑi ∗ (K) = (A4)
55 ∀0i(m) ― ζ .∀max(m)
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3 1 𝑛
4 𝜔𝑖 = 𝑛∑𝑚 = 1ϑ𝑖(𝑚) (𝐴5)
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6 Where 𝜔i - Grey grade for the ith experiment
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n- number of response characteristics.
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Probability Plot of MRR Probability Plot of Rz
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Normal - 95% CI Normal - 95% CI
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99 99
13 Mean 3.767 Mean 15.33
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14 StDev 2.083 StDev 1.152
95 N 9 95 N 9
15 AD 0.411 AD 0.396
90 90
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18 70 70
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28 MRR Rz
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31 Fig. A1 Probability plots for (a) MRR (b) SR at 95% confidence level
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Scatterplot of Pon vs Poff, Poff vs SV, Pon vs SV
6 Pon*Poff Poff*SV MRR
7 130.0 55.0 1.55
8 1.60
127.5 52.5 2.15
9
2.40
10 125.0 50.0 3.15
11
W
4.45
12 122.5 47.5 5.05
13 6.70
or
14 120.0 45.0 6.85
15 45.0 47.5 50.0 52.5 55.0 60.0 62.5 65.0 67.5 70.0
16 Pon*SV
ld
17 130.0
18
127.5
19
Jo
20
125.0
21
22 122.5
ur

23
24 120.0
25 60.0 62.5 65.0 67.5 70.0
na

26
27 Fig. A2 Scatter plot for MRR
28
lo

29
30 Scatterplot of Pon vs Poff, Pon vs SV, Poff vs SV
31 Pon*Poff Pon*SV Rz
fE

32 130.0 13.8833
33 14.3800
34 127.5 14.7033
14.8000
ng

35
125.0 15.1433
36 15.1533
37 122.5 15.6600
38 16.8300
ine

39 120.0 17.4567
40 45.0 47.5 50.0 52.5 55.0 60.0 62.5 65.0 67.5 70.0
41 Poff*SV
42 55.0
er

43
44 52.5
45
ing

50.0
46
47
47.5
48
49 45.0
50 60.0 62.5 65.0 67.5 70.0
51
52
53
Fig. A3 Scatter Plot for Rz
54
55
56
57
58
59
60