Optimizing EDM Performance with Cu-MWCNT Composite Tools: Taguchi-Based GRA Approach Prosun Mandal, Akash Nag Developments in Electric Discharge Machining, 2026 Among various non-traditional machining processes, electrical discharge machining (EDM) stands out as one of the most significant and widely utilized techniques. This process removes material by employing a series of discontinuous electric discharges, which erode the workpiece to create a replica of the tool’s shape. The entire operation takes place within a dielectric fluid environment, ensuring precision and efficiency [1]. The machining performance is evaluated based on two important output responses: the rate of material removal normally termed as MRR and the rate of wear of electrode material termed as EWR. The enhancement of MRR and reduction of EWR are the basic requirements for achieving more effective, efficient, and economical EDM performance [2]. Four important controlling factors, namely, pulse-on-time, discharge current, voltage, and duty cycle, govern the performance of EDM [3]. Machining performing with the optimal parameters is one of the best ways to get better machining performance [4–8]. In EDM, a proper combination of machining parameters selection has an important role in getting maximum MRR and minimum EWR. Solving this type of multi-objective optimization problem is still a challenging job [9]. Tang and Du [10] used the Taguchi-based grey relational analysis (GRA) technique to resolve the multi-objective optimization problem for the EDM operation of titanium-based composite material. Mia et al. [11] solved the problem with the multiple objectives of turning process using the Taguchi-based GRA technique. The issue related to the single-objective optimization problem was easily overcome by this method. Das et al. [12] used the Taguchi-based GRA technique to optimize MRR and SR simultaneously. Kuram and Ozcelik [13] also successfully used Taguchi based GRA technique to obtain the optimal parameter setting for micro-milling operations. Singh [14] applied design of experiments (DOE) and the Taguchi-based GRA technique for finding optimized EDM process parameters for machining of 6061Al/Al2O3p/20P aluminium metal matrix composites. Huang et al. [15] used the grey Taguchi technique for the optimization of multiple performance parameters of EDM operation during machining of titanium alloy.
Multi-Objective Optimization of Wire-EDM Using ANN-NSGA-II Hybrid Approach Abhijit Saha, Dipika Sarkar, Prosun Mandal Developments in Electric Discharge Machining, 2026 The present research work is focused on solving the multi-objective optimization problem of wire electrical discharge machining (wire-EDM) for the machining of nanostructured hardfaced material using an artificial neural network (ANN)- non-dominated sorting genetic algorithm II (NSGA-II) hybrid approach. Hardfacing is one of the cost-effective methods for improving performance as well as increasing the reliability of the components. Due to the presence of nano-particles, the hardness of the nanostructured hardfaced material drastically increased. Wire-EDM is one of the useful techniques to machine hard materials. For increasing the machining performance of hardfaced material, the proper selection of wire-EDM parameters is needed. The ANN is an artificial intelligence technique, which has an efficient ability to model any non-linear complicated process. The ANN technique was used for developing a prediction model of a complicated wire-EDM process, and further, this prediction model was used as a fitness function of a multi-objective genetic algorithm (GA) to find the optimal process parameters. The ANN model with 14 and 3 neurons in each of the 2 hidden layers predicts the responses most efficiently. A total of 35 sets of optimal parameters were found using NSGA-II.
Preface Developments in Electric Discharge Machining, 2026
Multi-objective optimization of laser-welded joints between AZ31B and fabricated nylon 66 composite sheets Nirvik Banerjee, Prosun Mandal, Amit Ratan Biswas, Saikat Ranjan Maity Welding International, 2026 This study investigates the overlapped laser welding of AZ31B magnesium alloy and graphene oxide (GO)-reinforced Nylon 66 composites. The research emphasizes the quantitative assessment of weld morphology, interface of bonding mechanisms, and the modes of failure. Utilizing a pseudo-pulsed fiber laser operating in continuous mode, factors such as laser power, welding speed, and spot diameter were optimized. Quantitative analysis showed distinct weld regions, including elongated fibrils and polymer micro-voids. Bonding occurred mainly through melting–reflow and mechanical interlocking. Controlled thermal gradients minimized polymer degradation, while high-purity argon shielding prevented oxidation and improved weld quality. Tensile tests post-welding indicated ultimate tensile strength (UTS) values ranging from 32-34 MPa, reflecting the effectiveness of the optimized parameters. Response Surface Methodology (RSM) was employed to develop mathematical models correlating input parameters to output properties, facilitating a multi-objective optimization strategy incorporating NSGA-II and TOPSIS. This approach predicted an optimal combination of approximately 512.70 W laser power, 574.39 mm/min welding speed, and a 1.5 mm spot diameter, achieving mean absolute errors of 3.37% for modulus and 1.7% for UTS in confirmation tests. This integrated methodology significantly enhances weld quality and provides valuable insights for developing high-performance joints in advanced engineering applications.
Optimization of laser welding process parameters for AISI 316L to Ti-6Al-4V dissimilar joints using RSM-MOPSO-TOPSIS technique Amit Ratan Biswas, Prosun Mandal, Nirvik Banerjee, Nitai Chandra Adak, Saikat Ranjan Maity Engineering Research Express, 2025 Titanium and stainless steel are globally used in the aerospace and automotive sectors for their exceptional corrosion resistance and mechanical properties. Welding of these alloys is a big challenge due to the formation of brittle intermetallic layers at their joining interfaces. Traditional methods like ultrasonic and resistance spot welding are unsuitable because of their inability to control heat input, lack of flexibility, limited repeatability, and the need for physical contact between tools and workpieces. To overcome these problems, the laser welding method can be utilized to achieve a high-performance welded joint. In the present study, titanium (Ti6Al4V) and steel (AISI 316L) alloys have been welded using a solid-state fiber laser. The welding parameters, including laser power, beam offset, and welding speed, are optimized using Response Surface Methodology (RSM) integrated with the Multi-Objective Particle Swarm Optimization (MOPSO) technique. The RSM-MOPSO generates a set of optimal solutions. To quantify the best parametric set, TOPSIS (Technique for Order of Preference by Similarity to Ideal Solution) is further adapted from the Pareto front. The experimental results show that the beam offset and laser power greatly affect the ultimate tensile strength and microhardness of the welded joint, respectively. In addition, multi-objective optimization results are validated experimentally, which demonstrate optimal conditions at 1 mm sec−1 welding speed, 0.5 mm beam offset, and 328.50 W laser power to achieve superior ultimate tensile strength and microhardness of the welded joints.
Sustainable Nanononwoven Electrospun Fabric from Virgin and Recycled Nylon Waste and Its Reinforcement by Graphene Oxide: A Study on Mechanical Characteristics Nirvik Banerjee, Prosun Mandal, Tapas Kumar Ghosh, Abhishek Sen, Amit Ratan Biswas, Saikat Ranjan Maity, Dipankar Chattopadhyay ACS Sustainable Chemistry and Engineering, 2025 The present research intends to fabricate electrospun nylon-66 (N66) in both virgin (N66) and recycled N66 (RN66) nanofibers with integrated graphene oxide (GO) reinforcement for environmental sustainability. Subsequent mechanical and thermal performances of the composite nanofibers were studied. Differential scanning calorimetry, thermogravimetric analysis, scanning electron microscopy (SEM), transmission electron microscopy (TEM), Fourier transform infrared spectroscopy, Raman spectroscopy, and X-ray diffraction analyses of GO, N66, RN66, and RN66 with varying weight percentages of GO were performed, while SEM and TEM results of the nanofibers revealed effective dispersion of GO within the matrix. The impact of GO on the mechanical properties of nanocomposites, particularly tensile strength, indicated that 0.5% GO enhanced ultimate tensile stress by 7.53% compared to N66 and by 51.52% relative to RN66. Thus, GO-incorporated RN66 nonwoven nanofibers can be effectively used for load-bearing applications.
Bi-objective optimization of an EDM process with Cu-MWCNT composite tool using single-valued neutrosophic grey relational analysis Prosun Mandal, Srinjoy Chatterjee, Shankar Chakraborty World Journal of Engineering, 2025 Purpose In many of today’s manufacturing industries, such as automobile, aerospace, defence, die and mould making, medical and electrical discharge machining (EDM) has emerged as an effective material removal process. In this process, a series of discontinuous electric discharges is used for removing material from the workpiece in the form of craters generating a replica of the tool into the workpiece in a dielectric environment. Appropriate selection of the tool electrode material and combination of input parameters is an important requirement for performance enhancement of an EDM process. This paper aims to optimize an EDM process using single-valued neutrosophic grey relational analysis using Cu-multi-walled carbon nanotube (Cu-MWCNT) composite tool electrode. Design/methodology/approach This paper proposes the application of grey relational analysis (GRA) in a single-valued neutrosophic fuzzy environment to identify the optimal parametric intermix of an EDM process while considering Cu-MWCNT composite as the tool electrode material. Based on Taguchi’s L9 orthogonal array, nine experiments are conducted at varying combinations of four EDM parameters, i.e. pulse-on time, duty factor, discharge current and gap voltage, with subsequent measurement of two responses, i.e. material removal rate (MRR) and tool wear rate (TWR). The electrodeposition process is used to fabricate the Cu-MWCNT composite tool. Findings It is noticed that both the responses would be simultaneously optimized at higher levels of pulse-on time (38 µs) and duty factor (8), moderate level of discharge current (5 A) and lower level of gap voltage (30 V). During bi-objective optimization (maximization of MRR and minimization of TWR) of the said EDM process, the achieved values of MRR and TWR are 243.74 mm3/min and 0.001034 g/min, respectively. Originality/value Keeping in mind the type of response under consideration, their measured values for each of the EDM experiments are expressed in terms of linguistic variables which are subsequently converted into single-valued neutrosophic numbers. Integration of GRA with single-valued neutrosophic sets would help in optimizing the said EDM process with the Cu-MWCNT composite tool while simultaneously considering truth-membership, indeterminacy membership and falsity-membership degrees in a human-centric uncertain decision-making environment.
Multi-objective optimization of laser-welded joints between AZ31B and fabricated nylon 66 composite sheets N Banerjee, P Mandal, AR Biswas, SR Maity Welding International, 1-21 , 2026 2026
Parametric Optimization of Autogenous Fiber Laser Welding Process for Ti6Al4V to AISI316L Joints AR Biswas, P Mandal, NC Adak, N Banerjee, SR Maity Journal of Materials Engineering and Performance 35 (12), 12117-12126 , 2026 2026
A critical review of laser welding of steel with titanium alloys for biomedical applications: challenges, developments, and properties AR Biswas, N Banerjee, P Mondal, SR Maity, B Sen, A Bhowmik, ... Philosophical Magazine Letters 105 (1), 2537089 , 2025 2025 Citations: 11
Optimization of laser welding process parameters for AISI 316L to Ti-6Al-4V dissimilar joints using RSM-MOPSO-TOPSIS technique AR Biswas, P Mandal, N Banerjee, NC Adak, SR Maity Engineering Research Express 7 (4), 045502 , 2025 2025 Citations: 2
Objective optimization of drilling of hybrid aluminium metal matrix composites using ANN NSGA-II hybrid approach RK Ghadai, A Baraily, K Logesh, G Sapkota, S Patil, S Das, P Mandal International Journal on Interactive Design and Manufacturing (IJIDeM) 19 (7 … , 2025 2025 Citations: 9
Sustainable Nanononwoven Electrospun Fabric from Virgin and Recycled Nylon Waste and Its Reinforcement by Graphene Oxide: A Study on Mechanical Characteristics N Banerjee, P Mandal, TK Ghosh, A Sen, AR Biswas, SR Maity, ... ACS Sustainable Chemistry & Engineering 13 (26), 9927-9940 , 2025 2025 Citations: 1
Bi-objective optimization of an EDM process with Cu-MWCNT composite tool using single-valued neutrosophic grey relational analysis P Mandal, S Chatterjee, S Chakraborty World Journal of Engineering 22 (3), 472-481 , 2025 2025 Citations: 7
Multi-objective optimization of an EDM process for Monel K-500 alloy using response surface methodology-multi-objective dragonfly algorithm P Mandal, S Mondal, R Cep, RK Ghadai Scientific Reports 14 (1), 20757 , 2024 2024 Citations: 29
A Review on Fabrication of Ceramic Composite Using Friction Stir Processing O Mutsuddi, MSI Shakib, P Mandal International Conference on Recent Advancements in Mechanical Engineering … , 2024 2024
Bi-objective Optimization of an EDM Process for Monel K-500 Alloy Using RSM-MOGA S Purkayastha, O Mutsuddi, P Mandal International Conference on Recent Advancements in Mechanical Engineering … , 2024 2024 Citations: 2
Experimental Investigation on the Performance of Copper-Based Mwcnt Composite Electrode in Edm P Mandal, SC Mondal Surface Review and Letters 29 (11), 2250141 , 2022 2022 Citations: 4
Performance analysis of copper-based MWCNT composite coated 316L SS tool in electro discharge machining P Mandal, SC Mondal Machining Science and Technology 25 (3), 422-437 , 2021 2021 Citations: 24
Multi-objective optimization of Cu-MWCNT composite electrode in electro discharge machining using MOPSO-TOPSIS P Mandal, SC Mondal Measurement 169, 108347 , 2021 2021 Citations: 56
Optimization of Surface Roughness in Centreless Grinding Process Based on Taguchi Method P Mandal Data-Driven Optimization of Manufacturing Processes, 37-47 , 2021 2021 Citations: 1
Enhancement of electro-thermal and mechanical properties for Cu-SWCNT coated 6061Al P Mandal, SC Mondal Surface Engineering 36 (2), 135-143 , 2020 2020 Citations: 9
Surface characteristics of mild steel using EDM with Cu-MWCNT composite electrode P Mandal, SC Mondal Materials and Manufacturing Processes 34 (12), 1326-1332 , 2019 2019 Citations: 65
Development and application of Cu-SWCNT nanocomposite–coated 6061Al electrode for EDM P Mandal, SC Mondal The International Journal of Advanced Manufacturing Technology 103 (5), 3067 … , 2019 2019 Citations: 25
Modeling and optimization of surface roughness in keyway milling using ANN, genetic algorithm, and particle swarm optimization G Ghosh, P Mandal, SC Mondal The International Journal of Advanced Manufacturing Technology 100 (5), 1223 … , 2019 2019 Citations: 138
Investigation on the performance of copper-coated 6061 aluminium alloy electrode in electric discharge machining P Mandal, SC Mondal Research into Design for a Connected World: Proceedings of ICoRD 2019 Volume … , 2019 2019 Citations: 17
Investigation of Electro-Thermal property for Cu-MWCNT composite coating on anodized 6061 aluminium alloy P Mandal, SC Mondal Applied Surface Science 454, 138-147 , 2018 2018 Citations: 43
MOST CITED SCHOLAR PUBLICATIONS
Modeling and optimization of surface roughness in keyway milling using ANN, genetic algorithm, and particle swarm optimization G Ghosh, P Mandal, SC Mondal The International Journal of Advanced Manufacturing Technology 100 (5), 1223 … , 2019 2019 Citations: 138
Surface characteristics of mild steel using EDM with Cu-MWCNT composite electrode P Mandal, SC Mondal Materials and Manufacturing Processes 34 (12), 1326-1332 , 2019 2019 Citations: 65
Multi-objective optimization of Cu-MWCNT composite electrode in electro discharge machining using MOPSO-TOPSIS P Mandal, SC Mondal Measurement 169, 108347 , 2021 2021 Citations: 56
Investigation of Electro-Thermal property for Cu-MWCNT composite coating on anodized 6061 aluminium alloy P Mandal, SC Mondal Applied Surface Science 454, 138-147 , 2018 2018 Citations: 43
Multi-objective optimization of an EDM process for Monel K-500 alloy using response surface methodology-multi-objective dragonfly algorithm P Mandal, S Mondal, R Cep, RK Ghadai Scientific Reports 14 (1), 20757 , 2024 2024 Citations: 29
Investigation of electro-thermal property of Cu-MWCNT-coated 316L stainless steel P Mandal, SC Mondal Surface Engineering 34 (9), 697–704 , 2017 2017 Citations: 26
Development and application of Cu-SWCNT nanocomposite–coated 6061Al electrode for EDM P Mandal, SC Mondal The International Journal of Advanced Manufacturing Technology 103 (5), 3067 … , 2019 2019 Citations: 25
Performance analysis of copper-based MWCNT composite coated 316L SS tool in electro discharge machining P Mandal, SC Mondal Machining Science and Technology 25 (3), 422-437 , 2021 2021 Citations: 24
Investigation on the performance of copper-coated 6061 aluminium alloy electrode in electric discharge machining P Mandal, SC Mondal Research into Design for a Connected World: Proceedings of ICoRD 2019 Volume … , 2019 2019 Citations: 17
An application of artificial neural network and particle swarm optimisation technique for modelling and optimisation of centreless grinding process P Mandal, SC Mondal International Journal of Productivity and Quality Management 20 (3), 344-362 , 2017 2017 Citations: 13
APPLICATION OF ARTIFICIAL NEURAL NETWORK FOR MODELING SURFACE ROUGHNESS IN CENTERLESS GRINDING OPERATION SC Mondal, P Mandal 5 th International & 26 th All India Manufacturing Technology, Design and … , 2014 2014 Citations: 12
A critical review of laser welding of steel with titanium alloys for biomedical applications: challenges, developments, and properties AR Biswas, N Banerjee, P Mondal, SR Maity, B Sen, A Bhowmik, ... Philosophical Magazine Letters 105 (1), 2537089 , 2025 2025 Citations: 11
Objective optimization of drilling of hybrid aluminium metal matrix composites using ANN NSGA-II hybrid approach RK Ghadai, A Baraily, K Logesh, G Sapkota, S Patil, S Das, P Mandal International Journal on Interactive Design and Manufacturing (IJIDeM) 19 (7 … , 2025 2025 Citations: 9
Enhancement of electro-thermal and mechanical properties for Cu-SWCNT coated 6061Al P Mandal, SC Mondal Surface Engineering 36 (2), 135-143 , 2020 2020 Citations: 9
Bi-objective optimization of an EDM process with Cu-MWCNT composite tool using single-valued neutrosophic grey relational analysis P Mandal, S Chatterjee, S Chakraborty World Journal of Engineering 22 (3), 472-481 , 2025 2025 Citations: 7
Experimental Investigation of Combined TIG-MIG Welding for 304 Stainless Steel Plates MS Khan, V Kumar, P Mandal, SC Mondal IOP Conference Series: Materials Science and Engineering 377 (1), 012067 , 2018 2018 Citations: 7
An application of particle swarm optimization technique for optimization of surface roughness in centerless grinding operation SC Mondal, P Mandal ICoRD’15–Research into Design Across Boundaries Volume 2: Creativity … , 2014 2014 Citations: 6
Application of genetic algorithm for the optimization of process parameters in keyway milling SC Mondal, P Mandal, G Ghosh International Conference on Research into Design, 71-86 , 2017 2017 Citations: 5
Experimental Investigation on the Performance of Copper-Based Mwcnt Composite Electrode in Edm P Mandal, SC Mondal Surface Review and Letters 29 (11), 2250141 , 2022 2022 Citations: 4
Experimental Investigation of Combined TIG-MIG Welding for 304 Stainless Steel Plates M Samir Khan, V Kumar, P Mandal, S Chandra Mondal IOP Conference Series: Materials Science and Engineering 377 (1), 012067 , 2018 2018 Citations: 3
