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The Scientific World Journal
Volume 2015 (2015), Article ID 895696, 6 pages
Research Article

Optimization of Processing Parameters in ECM of Die Tool Steel Using Nanofluid by Multiobjective Genetic Algorithm

1Department of Mechanical Engineering, Dr. Navalar Nedunchezhiyan College of Engineering, Tholudur 606 303, India
2Department of Mechanical Engineering, Thanthai Periyar Government Institute of Technology, Vellore 2, India
3Department of Mechanical Engineering, UCSI University, North Wing, 56000 Kuala Lumpur, Malaysia

Received 29 November 2014; Accepted 5 January 2015

Academic Editor: Venkatesh Jaganathan

Copyright © 2015 V. Sathiyamoorthy et al. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.


Formation of spikes prevents achievement of the better material removal rate (MRR) and surface finish while using plain NaNO3 aqueous electrolyte in electrochemical machining (ECM) of die tool steel. Hence this research work attempts to minimize the formation of spikes in the selected workpiece of high carbon high chromium die tool steel using copper nanoparticles suspended in NaNO3 aqueous electrolyte, that is, nanofluid. The selected influencing parameters are applied voltage and electrolyte discharge rate with three levels and tool feed rate with four levels. Thirty-six experiments were designed using Design Expert 7.0 software and optimization was done using multiobjective genetic algorithm (MOGA). This tool identified the best possible combination for achieving the better MRR and surface roughness. The results reveal that voltage of 18 V, tool feed rate of 0.54 mm/min, and nanofluid discharge rate of 12 lit/min would be the optimum values in ECM of HCHCr die tool steel. For checking the optimality obtained from the MOGA in MATLAB software, the maximum MRR of 375.78277 mm3/min and respective surface roughness Ra of 2.339779 μm were predicted at applied voltage of 17.688986 V, tool feed rate of 0.5399705 mm/min, and nanofluid discharge rate of 11.998816 lit/min. Confirmatory tests showed that the actual performance at the optimum conditions was 361.214 mm3/min and 2.41 μm; the deviation from the predicted performance is less than 4% which proves the composite desirability of the developed models.