Analysis of Output Performance Measures of Coating in EDM by Non-Dominated Sorting Using Pareto Front

This experimental work presents a study of parametric effects during pattern generation under the reverse EDM process. A user-defined pattern is created on aluminum (Al) 6061 surface. The particles are deposited to the work surface using a green compact powder metallurgy (PM) tool. The deposition process is carried out by transferring tungsten (W) and copper (Cu) particles at the chosen region on the Al-6061 surface. The influence of pulse on-time (T[Formula: see text] is observed on the output responses i.e., TWR, MDR, Ra and ED of the generated pattern. The experimental results show the significant effects of T on on the output parameters. A multi-objective optimization is carried out using nondominated sorting based on the Pareto front followed by evaluating the fitness to identify the optimal output combination corresponding to the input parameters. All output parameters are assigned equal weightage. Several output combinations are evaluated, yielding an optimal T on of 1000[Formula: see text] [Formula: see text]s for combinations such as ‘MDR and Ra’, ‘MDR and ED’, ‘TWR and Ra’, ‘TWR, MDR and ED’, ‘TWR, MDR and Ra’ and ‘TWR, MDR, Ra and ED’. Conversely, an optimal T on of 21[Formula: see text] [Formula: see text]s is identified for the combination ‘TWR, Ra and ED,’ while a T on of 100[Formula: see text] [Formula: see text]s is determined as optimal for the combination ‘TWR and ED’. At T on of 1000[Formula: see text] [Formula: see text]s, TWR of 538.1[Formula: see text]mg/min, MDR of 159[Formula: see text]mg/min, Ra of 5.2[Formula: see text] [Formula: see text]m and ED of 76.89[Formula: see text] [Formula: see text]m is obtained. Similarly, at T on of 21[Formula: see text] [Formula: see text]s, TWR of 130.2[Formula: see text]mg/min, MDR of 19.4[Formula: see text]mg/min, Ra of 4.30[Formula: see text] [Formula: see text]m and ED of 29.35[Formula: see text] [Formula: see text]m is obtained. At T on of 100[Formula: see text] [Formula: see text]s, TWR of 328.2[Formula: see text]mg/min, MDR of 42.9[Formula: see text]mg/min, Ra of 5.20[Formula: see text] [Formula: see text]m and ED of 37.83[Formula: see text] [Formula: see text]m is obtained. The surface topography is displayed by FESEM and EDS investigations, which also validate the material transfer to the work surface.