A unified framework for selecting parameters in electro discharge boring operation with radial tool movement using hybrid AHP-WASPAS optimization techniques

Electrodischarge machining (EDM), is a widely used nontraditional material removal technique of conducting material. This method has been utilized in the current study to perform boring operations on Inconel 718 super alloys. Inconel 718 is widely used in the aerospace, automotive, and energy industries due to its superior mechanical qualities, corrosion resistance, and high-temperature performance. These advantages make Inconel 718 an ideal material for researching efficient manufacturing and innovative technical applications. A radial orbital tool path has been used for the mobility of the tool and it was guided and controlled to complete the boring process. By applying Taguchi's L27 design, experiments have been carried out to determine the effects of orbital along with nonorbital factors on the responses like material removal rate, tool wear rate, and surface roughness (Ra). A boring operation with EDM differs from traditional machining processes in that it produces a superior surface finish, can machine complicated geometries, and is suitable for high-hardness materials. An efficient optimization strategy is essential for reaching the optimal level of process parameters. The weighted aggregated sum product assessment (WASPAS) technique, which integrates with analytical hierarchy process, is employed to analyze an ideal parametric combination (input current = 21A; pulse on time = 195 µs; pulse off time = 32 µs; orbital speed = 0.13 mm/s; orbital radius = 1.5 mm; machining time = 1.034 s, and flushing time = 0.067 s). The optimized parameters resulted in a 27.16% improvement in material removal rate, a significant reduction of 40.82% in tool wear rate and 20.01% reduction in Ra compared to machining at higher parameter levels. Additionally, the rank reversal tests were conducted as a qualitative evaluation process for the outcomes of the suggested hybrid approach. With just one rank reversal, the findings validate the robustness of the specified decisional method.