Grey-based Taguchi method for optimisation of multiple characteristics in electrochemical deburring process

In the present study, a multi-objective optimisation technique, based on Taguchi method in combination with grey relational analysis, has been proposed and adopted in search of an optimal parametric combination during electrochemical deburring (ECD) of die steel. Deburring voltage, gap between tool and burr tip, electrolyte concentration and time are considered as input parameters when the performance characteristics include change in burr height and base material removal are taken into consideration. Taguchi's L16 orthogonal array design is chosen for the experiments. An optimal parameter combination of ECD process is obtained by grey relational grade acquired from grey relational analysis (GRA). Optimal ECD parameters for multiple performance characteristics have been derived by the Taguchi method using grey relational grade as the quality index. Optimal setting has been validated using confirmatory test. Considering these ECD parameters, verification of the improvement in the quality characteristics was made with a confirmation test with respect to the chosen initial or reference parameter setting. The outcomes of these experiments indicate the application feasibility of the proposed optimisation technique for continuous improvement in electrochemical deburring process.