Non-conventional optimization techniques in optimizing non-traditional machining processes: A review

With the ever-increasing demands for high surface finish and complex shape geometries, conventional metal removal methods are now being replaced by non-traditional machining (NTM) processes. These NTM processes use energy in its direct form to remove materials in the form of atoms or molecules to obtain the required accuracy and burr-free machined surface. In order to exploit the optimal capabilities of the NTM processes, it is often required to determine the best possible combinations of their controllable parameters. Different non-conventional optimization techniques have been used for dealing with these process optimization problems because of their inherent advantages and capabilities for arriving at the almost global optimal solutions. This paper reviews the applications of different non-conventional optimization techniques for parametric optimization of NTM processes. It is observed that electrical discharge machining processes have been optimized most number of times, followed by wire electrical discharge machining processes. In most of the cases, the past researchers have preferred to maximize material removal rate. Genetic algorithm has been found to be the most popular non-conventional optimization technique.