Process Parameter Optimization of Abrasive Jet, Ultrasonic, Laser Beam, Electrochemical, and Plasma Arc Machining Processes Using Optimization Techniques: A Review

Abstract

A comprehensive literature review of the optimization techniques used for the process parameter optimization of Abrasive Jet Machining (AJM), Ultrasonic Machining (USM), Laser Beam Machining (LBM), Electrochemical Machining (ECM), and Plasma Arc Machining (PAM) are presented in this review article. This review article is an extension of the review work carried out by previous researchers for the process parameter optimization of non-traditional machining processes using various advanced optimization algorithms. The review period considered for the same is from 2012 to 2022. The prime motive of this review article is to find out the sanguine effects of various optimization techniques used for the optimization of various considered objectives of selected non-traditional machining processes in addition to deemed materials and foremost process parameters. It is found that most of the researchers have more inclination towards the minimization of Surface Roughness (SR) compared to the maximization of the Material Removal Rate (MRR) as their objective function for AJM and PAM. Similarly, for USM and ECM, researchers are more inclined towards the maximization of MRR compared to the minimization of SR. Minimization of the Heat-Affected Zone (HAZ) and SR are the two most considered response parameters for the LBM and its allied processes. This study provides ready-to-use details on the use of various advanced optimization techniques for AJM, USM, LBM, ECM, and PAM, with the considered workpiece material, process parameters, and imposed limitations. This review work is carried out on such a large scale that it will help future researchers and industrialists to decide their research direction.