Optimization of Sustainable Electrochemical Machining Parameters for Polymer based Materials Using AHP Integrated TOPSIS Method

Year : 2026 | Volume : 14 | Special Issue 01 | Page : 1048 1059
    By

    S. Chandrasekhar,

  • M. V. Ramesh,

  • Arief Sheik,

  • K. Srirama murthy,

  • K.S.B.S.V.S. Sastry,

  • Shaik Sohail,

  1. Associate Professor, Department of Mechanical Engineering, Sri Vasavi Engineering College, Tadepalligudem, Andhra Pradesh, India
  2. Professor, Department of Mechanical Engineering, Sri Vasavi Engineering College, Tadepalligudem, Andhra Pradesh, India
  3. Assistant Professor, Department of Mechanical Engineering, Sri Vasavi Engineering College, Tadepalligudem, Andhra Pradesh, India
  4. Assistant Professor, Department of Mechanical Engineering, Sri Vasavi Engineering College, Tadepalligudem, Andhra Pradesh, India
  5. Associate Professor, Department of Mechanical Engineering, Sri Vasavi Engineering College, Tadepalligudem, Andhra Pradesh, India
  6. UG Student, Department of Mechanical Engineering, Sri Vasavi Engineering College, Tadepalligudem, Andhra Pradesh, India

Abstract

The current paper describes the use of the AHP-TOPSIS method to optimize process parameters in sustainable electrochemical machining of polymer composites. Combine lightweight polymer matrices with reinforcing particles or fibers such as TiB₂, SiC, or Al₂O₃, offering high strength-to-weight ratio, corrosion resistance, and design flexibility, making them ideal for aerospace and automotive applications. Non-conductive and heterogeneous nature poses challenges during electrochemical machining, as it affects current distribution and material removal behavior, requiring careful optimization of process parameters to achieve uniform machining quality. Results show that AHP integrated with TOPSIS effectively handled multiple-response objectives for parameters such as electrolyte concentration, voltage, and current. AHP assigned 72.35% weight to specific energy consumption, 19.32% to overcutting, and 8.33% to material removal rate. TOPSIS identified optimal levels as 3 moles electrolyte concentration, 14 V, and 2 A. Interaction plots revealed current as the most influential factor, followed by electrolyte concentration and voltage. Microscopic analysis of polymer composites confirmed uniform hole radius with nano burrs at the edge, caused by current and tool insulation issues. Confirmation experiments showed a 3% improvement in closeness coefficient over initial settings. Overall, the AHP-TOPSIS approach enhanced sustainable machining performance of polymer composite and can be applied to optimize other processes with multiple responses by adjusting response weights.

Keywords: Polymer composites, electrochemical machining, AHP-TOPSIS method, sustainable machining.

[This article belongs to Special Issue under section in Journal of Polymer & Composites (jopc)]

How to cite this article:
S. Chandrasekhar, M. V. Ramesh, Arief Sheik, K. Srirama murthy, K.S.B.S.V.S. Sastry, Shaik Sohail. Optimization of Sustainable Electrochemical Machining Parameters for Polymer based Materials Using AHP Integrated TOPSIS Method. Journal of Polymer & Composites. 2026; 14(01):1048-1059.
How to cite this URL:
S. Chandrasekhar, M. V. Ramesh, Arief Sheik, K. Srirama murthy, K.S.B.S.V.S. Sastry, Shaik Sohail. Optimization of Sustainable Electrochemical Machining Parameters for Polymer based Materials Using AHP Integrated TOPSIS Method. Journal of Polymer & Composites. 2026; 14(01):1048-1059. Available from: https://journals.stmjournals.com/jopc/article=2026/view=236676


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Special Issue Subscription Original Research
Volume 14
Special Issue 01
Received 14/10/2025
Accepted 15/11/2025
Published 10/02/2026
Publication Time 119 Days
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