Modeling and Optimization of Ultrasonic Machining Process Using a Novel Evolutionary Algorithm

Ultrasonic machining (USM) is one of the non-conventional techniques for machining of hard and brittle materials like glass, ceramics, and ceramic matrix composites. The objective of the study includes the investigation of material removal rate (MRR), hole oversize (HOS), and circularity of holes (COH) during USM of soda lime glass and finding out the optimal parametric condition by an evolutionary algorithm. Taguchi philosophy was employed to carry out experiments using the process parameters such as power rating, abrasive slurry concentration, and static load. A novel optimization algorithm called imperialist competitive algorithm (ICA) was used to obtain maximum MRR and minimum HOS and COH. This algorithm is inspired by the imperialistic competition and has several advantages over other evolutionary algorithms like its simplicity, less computational time, and accuracy in predicting the results. The Technique for order of preference by similarity to ideal solution (TOPSIS) is utilized to convert these multiple performance characteristics to a single response. Moreover, the prediction outcomes of this TOPSIS integrated ICA methodology demonstrates excellent conformity with the experimental values and can be applied to solve complex problems.