Taguchi Based Grey Approach for Optimizing the Advanced Machining of Nickel Alloys in Manufacturing of Automotive Parts

The objective of this research is to develop an optimization technique for the Electrochemical Drilling process on Inconel 625 material, considering various performance factors. The Taguchi approach, along with Grey Relational Analysis (GRA), forms the basis for optimization. Inconel 625 has a wide range of uses in industries such as aerospace, nuclear, and marine, especially in harsh environments. The experimental trials conducted in accordance with Taguchi's approach have utilized three machining variables: feed rate, electrolyte flow rate, and electrolyte concentration. When doing this examination, we analyze not only the rate at which material is removed and the roughness of the surface, but also other characteristics that indicate performance, such as overcut, shape, and orientation tolerance. The analytical findings indicate that the feed rate is the primary factor that directly impacts the required performance standards. Regression models are constructed to make predictions, and performance measures are established to assess their effectiveness. Furthermore, the confirmation test was conducted to verify the results acquired using the GRA approach. The test results unequivocally showed that the new procedure is markedly superior to the prior one.