ORIGINAL ARTICLE A hybrid approach for multi-performance optimization of the electro-chemical honing process A. K. Dubey Received: 17 May 2007 / Accepted: 28 January 2008 # Springer-Verlag London Limited 2008 Abstract Electro-chemical honing (ECH) is a unique hybrid electrolytic precision micro-finishing technology that combines electro-chemical machining and conventional honing actions in a single operation to provide simulta- neously controlled functional surface-generation and fast material removal capabilities. This paper presents a Taguchi loss function-based hybrid strategy for the multi- performance optimization of ECH process. The proposed strategy utilizes a radial basis function neural network (RBFNN) for the process parametric mapping with the loss functions of ECH multi-performance characteristics deter- mined through a Taguchi matrix robust experimental design. The network outputs are then unified using desirability function (DF) approach to provide an objective function to genetic algorithm (GA). Finally, GA predicts the optimal process parametric settings for multi-performance optimiza- tion of ECH. Simulated results confirm the feasibility of the strategy and show good close agreement with actual experimental results over a wide range of machining conditions employed in the process. Keywords Desirability function . Electro-chemical honing . Genetic algorithms . Multi-performance optimization . Radial basis function neural network Nomenclature AI Artificial intelligence ANFIS Adaptive network-based fuzzy inference system C Current intensity (Ampere) DF Desirability function DIR Diametral increase rate EA Evolutionary algorithms EC Electrolyte concentration (g/L) ECH Electro-chemical honing F Electrolyte flow rate (L/min) G Abrasive stick grit size GA Genetic algorithm IEG Inter-electrode gap NSGA Non-dominated sorting genetic algorithm PCA Principal component analysis PIOR Percent improvement in out-of-roundness PIR a Percent improvement in R a R a Arithmetic average surface roughness RBFNN Radial basis function neural network S/N ratio Signal-to-noise ratio SOP Stick-out pressure (kPa) SR Rotary-to-reciprocating speed ratio T Electrolyte inlet temperature (°C) 1 Introduction Electro-chemical honing is a unique hybrid electrolytic precision micro-finishing technology that combines electro- chemical machining and conventional honing actions in a single operation to provide the controlled functional surface generation and fast material removal capabilities simulta- neously [1]. ECH possesses several unique features, including the flexibility to control the work surface characteristics; much higher productivity as compared to conventional honing and even internal grinding; nano- finish capability with impressive surface characteristic parameters and precisely controlled part sizes and shape deviations; and ability to improve surface integrity. Owing Int J Adv Manuf Technol DOI 10.1007/s00170-008-1422-8 A. K. Dubey (*) NTPC Limited Unchahar, AE/A-166, NTPC Unchahar, Raebareli 229 406, India e-mail: abhay_58117@rediffmail.com