Prediction of recast layer for EDM drilled hole in Ti6Al4V sheet using artificial intelligence Tasnim Arif, Amit Sharma Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture, 2026 Electrical Discharge Drilling (EDD) is widely used for machining difficult-to-cut titanium alloys. However, thermal damage in the form of recast layer thickness (RLT) significantly affects the surface integrity and reliability of drilled components. This study develops an artificial intelligence-based predictive framework using Adaptive Neuro-Fuzzy Inference System (ANFIS) integrated with Fuzzy C-Means (FCM) clustering and hybrid optimization techniques to model RLT during EDD. Experiments were conducted using a full factorial design considering discharge current, pulse-on time, pulse-off time, and dielectric pressure. A total of 81 experiments were performed, where 60 datasets were used for training and 21 for testing. Among all models, ANFIS achieved the best prediction accuracy (Mean average error = 0.0497, Root mean square error = 0.041, Variance accounted for = 82.33%, and coefficient of determination R 2 = 0.816), outperforming hybrid FCM models ( R 2 ≈ 0.56–0.68). Parametric analysis revealed that higher discharge current and pulse-on time increase RLT, whereas higher pulse-off time and dielectric pressure reduce RLT due to improved cooling and flushing. The proposed intelligent framework enables reliable prediction of recast layer formation and supports optimization of EDM drilling parameters for improved surface integrity of titanium alloy components.
Parametric investigation in electrical discharge drilling of Ti-alloy using ANFIS Md Tasnim Arif, Amit Sharma Concurrent Engineering Research and Applications, 2025 The need for precise and efficient manufacturing processes is rapidly growing worldwide for the conversion of biomaterials into highly accurate and precise artificial implants and medical devices. Ti-based alloys are particularly used for implants and bone plate materials because they have good mechanical as well as biological properties. Predicting increased productivity during EDD of Ti-6Al-4V alloy with less tool damage and improved dimensional accuracy of the drilled hole is proposed in the study. Process performance was evaluated in terms of metal removal rate (MRR), tool wear rate (TWR), and hole taper (HT), as functions of discharge current, pulse-on time, pulse-off time, and dielectric pressure. A hybrid modeling approach combining Adaptive Neuro-Fuzzy Inference System (ANFIS) model integrating artificial neural networks (ANN) and fuzzy logic (FL) was employed to capture the non-linear relationships among variables. The model exhibited a close agreement with experimental results, with prediction errors 1.04% for MRR, 5.65% for TWR and 4.12% for HT. Discharge current and dielectric pressure were identified as the most influential parameters. While the proposed approach effectively predicts process behavior within the experimental range, its applicability beyond the tested parameter domain requires further validation. The study demonstrates the potential of hybrid modeling for achieving enhanced precision and efficiency in the fabrication of biomedical components.
Investigation of excellence in Nd-YAG laser cutting of Al6061-T6 thin sheet using GRA coupled with PCA Amit Sharma, Priyanka Joshi, Basanta Kumar Bhuyan, Rakesh Kumar Phanden Engineering Research Express, 2024 Cutting flying materials with minimum deviations and metallurgical damages is always preferred for airframe work in aircraft industries. In the present scenario, the laser cutting process has become the preferred choice for fine cutting of sheet materials with close tolerances. This paper reports the investigation of excellence in pulsed laser cutting of Al-alloy (Al6061-T6) sheet. Five quality characteristics for quantifying the dimensional accuracy (i.e., kerf width and deviation at the top and bottom side) and metallurgical damage (i.e., heat-affected zone) have been considered for the proposed work. These characteristics depend on the lamp current, laser parameters (pulse width and frequency), and relative motion between the sheetmetal and laser source. The experiments were performed using the design of the experiments technique. Further, the results of laser cutting have been optimized by using grey relational analysis (GRA) coupled with principal component analysis (PCA). The application of GRA-PCA is found capable of optimizing all five process responses at a time. The unevenness within the kerf is reduced by 22% and 32% at the top and bottom sides, respectively.
Empirical modeling and optimization of kerf characteristics in Nd-YAG laser cutting of Al 6061-T6 sheet Amit Sharma, Priyanka Joshi, Kuldeep K Saxena Proceedings of the Institution of Mechanical Engineers Part E Journal of Process Mechanical Engineering, 2024 Al alloys are the second most useful metal worldwide after the steel due to its high strength-to-weight ratio and corrosion resistance properties. In the present scenario, for creating contours in the sheet metals with close tolerances and high precision, laser beam cutting is preferred. During laser beam cutting of Al alloys, the reflectivity of the alloy possesses some difficulties to absorb the laser light. Such problems can be avoided using the shorter wavelength laser. This paper presents the modeling and optimization of kerf characteristics in Nd-YAG laser cutting of Al 6061-T6 sheet. In this study, kerf width (top and bottom side) and top kerf deviation are considered as kerf characteristics which are the functions of lamp current, pulse width, pulse frequency, and cutting speed. Box–Behnken design has been used for conducting the experiments and the experimental results have been further used for developing the response surface models and optimizing the responses using response surface methodology and grey relational analysis, respectively. Application of grey relational analysis has reduced the bottom kerf width by 12.5% and 7.75% along with straight and curved cut profiles respectively.
Investigation of parametric influences during the cutting of contours in 6061-T6 aluminium alloy sheet using a pulsed Nd:YAG laser Lasers in Engineering, 2020
Modelling and optimization of cut quality characteristics for pulsed Nd:YAG laser curved profile cutting of Ni-based superalloy thin sheet Lasers in Engineering, 2015