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<p>Aluminium alloy-based composites are widely utilized in aerospace and automotive applications due to their superior mechanical properties and lightweight nature. However, the machining of these composites remains challenging due to the presence of hard reinforcement particles. Hence, the present study focuses on optimizing the electric erosion or discharge machining (EDM) parameters for an Al-0.8Fe-0.7Si alloy composite reinforced with 15 wt.% TiO<sub>2</sub> particles using the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) method. The aluminium-based composite was fabricated through the stir casting process, and scanning electron microscopy (SEM) analysis confirmed the uniform dispersion of TiO<sub>2</sub> particles within the matrix. The EDM parameters namely, peak current (I<sub>p</sub>), pulse-on time (T<sub>on</sub>), and pulse-off time (T<sub>off</sub>), were selected as input parameters, while material removal rate (MRR), surface roughness (SR), and tool wear rate (TWR) were chosen as output responses. Machining experiments were conducted based on a Taguchi L9 array design using a copper (Cu) electrode. The TOPSIS analysis identified the optimal variable combinations as I<sub>p</sub> = 15 amps, T<sub>on</sub> = 300&#xa0;µs, and T<sub>off</sub> = 60&#xa0;µs, which resulted in higher MRR (0.4525&#xa0;g/min), lower SR (3.737&#xa0;µm), and reduced TWR (0.0372&#xa0;g/min). ANOVA results revealed that I<sub>p</sub> is the most consequence factor, contributing 40.3%, followed by T<sub>on</sub> (27.3%) and T<sub>off</sub> (18.8%). Furthermore, the interaction plot indicated that the combined effect of I<sub>p</sub> and T<sub>on</sub> has a substantial impact on the machining responses.</p> Graphical Abstract <p></p>

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Multi-Criteria Optimization of Electric Erosion Machining Performance of Al-0.8Fe-0.7Si Alloy Composites Using TOPSIS Decision-Making Approach

  • 期刊论文

  • 发表日期：

    2026年7月6日

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  • R. Muruganandham,
  • J. Dinesh,
  • J. Joshua Selvakumar,
  • A. Karthikeyan,
  • S. V. Alagarsamy

摘要

Aluminium alloy-based composites are widely utilized in aerospace and automotive applications due to their superior mechanical properties and lightweight nature. However, the machining of these composites remains challenging due to the presence of hard reinforcement particles. Hence, the present study focuses on optimizing the electric erosion or discharge machining (EDM) parameters for an Al-0.8Fe-0.7Si alloy composite reinforced with 15 wt.% TiO2 particles using the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) method. The aluminium-based composite was fabricated through the stir casting process, and scanning electron microscopy (SEM) analysis confirmed the uniform dispersion of TiO2 particles within the matrix. The EDM parameters namely, peak current (Ip), pulse-on time (Ton), and pulse-off time (Toff), were selected as input parameters, while material removal rate (MRR), surface roughness (SR), and tool wear rate (TWR) were chosen as output responses. Machining experiments were conducted based on a Taguchi L9 array design using a copper (Cu) electrode. The TOPSIS analysis identified the optimal variable combinations as Ip = 15 amps, Ton = 300 µs, and Toff = 60 µs, which resulted in higher MRR (0.4525 g/min), lower SR (3.737 µm), and reduced TWR (0.0372 g/min). ANOVA results revealed that Ip is the most consequence factor, contributing 40.3%, followed by Ton (27.3%) and Toff (18.8%). Furthermore, the interaction plot indicated that the combined effect of Ip and Ton has a substantial impact on the machining responses.

Graphical Abstract