32 Int. J. Precision Technology, Vol. 7, No. 1, 2017 Copyright © 2017 Inderscience Enterprises Ltd. Analysis on electrochemical discharge machining during micro-channel cutting on glass B. Mallick, B.R. Sarkar*, B. Doloi and B. Bhattacharyya Production Engineering Department, Jadavpur University, Kolkata-700032, India Email: bijan.ju@gmail.com Email: sarkarbiplab_s@rediffmail.com Email: bdoloionline@rediffmail.com Email: bb13@rediffmail.com *Corresponding author Abstract: Modern industrial field of micro-machining has an attractive attention to increase the machinability of electrically non-conducting materials. Electrochemical discharge micro-machining process has the ability to machine high strength non-conducting brittle materials like glass. This paper shows a development of second-order correlation between the various machining criteria and different process parameters such as applied voltage, electrolyte concentration and inter-electrode gap (IEG). The analysis of variance (ANOVA) has been performed to find out the adequacy of the developed models. The research paper includes the effects of various process parameters on material removal rate (MRR), overcut (OC), heat affected zone (HAZ) and machining depth (MD) during micro-channel generation on glass. This paper also represents the single as well as multi-objective optimised results to determine the suitable parametric combination for maximum MRR and machining depth and minimum overcut and HAZ area using response surface methodology (RSM) and genetic algorithm (GA). Keywords: ECDM; electrochemical discharge machining; micro-channel; RSM; response surface methodology; GA; genetic algorithm; glass. Reference to this paper should be made as follows: Mallick, B., Sarkar, B.R., Doloi, B. and Bhattacharyya, B. (2017) ‘Analysis on electrochemical discharge machining during micro-channel cutting on glass’, Int. J. Precision Technology, Vol. 7, No. 1, pp.32–50. Biographical notes: B. Mallick is a Research Scholar of Production Engineering Department, Jadavpur University, Kolkata, India. He has more than five years of research as well as teaching experiences. He has published more than five research papers in reputed journals and presented many research works in international conferences. His research interest includes micro-machining and ECDM processes. B.R. Sarkar is an Assistant Professor of Production Engineering Department, Jadavpur University, Kolkata, India. He has published more than 25 international research papers including 10 research papers in reputed international journals. He has presented more than 15 papers in many prestigious conferences. He has guided several MTech theses and is supervising PhD theses also. His areas of research interest include