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This study investigates and optimizes electro discharge face grinding (EDFG) for processing Monel 400 alloy. The EDFG process is complex, and choosing the appropriate input process parameters is challenging. In this work, the central composite design (CCD) of response surface methodology (RSM) was used to plan the experiments, and analysis of variance (ANOVA) was used to identify the significance of process parameters. This work aimed to assess the influence of grinding wheel speed (GWS) along with other process parameters on response parameters and to optimize the process parameters for the EDFG process. The ANOVA confirmed that GWS significantly affects the response parameters. Finally, the Desirability approach and Genetic algorithm (GA) optimizations were employed and compared to determine the best optimal process parameter settings for the process, with the three different objective function weights related to material removal rate (MRR) and average surface roughness (ASR). The optimum conditions were identified and confirmed through validation experiments. The machined surfaces were also analyzed using scanning electron microscope (SEM) images to assess the effects of the suggested parameter combinations. The study concluded that the GA approach was more effective in optimizing the EDFG process. [ABSTRACT FROM AUTHOR]

Electrical discharge machining (EDM) is widely applied for machining difficult-to-cut materials in mold and die industries. However, the major limitations associated with the EDM are low productivity and poor surface integrity of the machined surfaces. In recent years, several developments have been applied to overcome such limitations of EDM. Electrical discharge grinding (EDG) is a hybrid machining process that simultaneously involves the spark erosion action of EDM and the mechanical abrasion action of the grinding wheel for the material removal purpose. The rotating motion of the grinding wheel also contributes to the easy removal of debris particles, thereby improving the material removal. It is evident from the literature that the rotating motion of the grinding wheel enhances the flushing mechanism resulting in better performance of the process. This paper aims to present a comprehensive review of the research carried out in EDG, highlighting the result of the experimental, modeling, and optimization techniques applied in this area. Initially, the background of EDM and the need for hybrid EDM processes have been presented. Then, a few hybrid EDM processes have been discussed, addressing their advantages and limitations. Further, the concept of EDG and electrical discharge diamond grinding (EDDG) has been discussed, along with the classification of the EDDG process. Finally, this paper explores the current research status and future research perspective in the area of EDG and EDDG processes. [ABSTRACT FROM AUTHOR]