A Decision-Supporting Multi-Objective Approach for Vibration-Assisted EDM of HARDOX 500 Using NSGA-II and AHP

Huu Danh Tran; Hoang Anh Le; Cong Danh Nguyen; Van Thanh Dinh; Tat Loi Mai; Manh Cuong Nguyen

doi:10.48084/etasr.13933

Authors

Huu Danh Tran Vinh Long University of Technology Education, 73 Nguyen Hue Street, Vinh Long City 85100, Vietnam
Hoang Anh Le Vinh Long University of Technology Education, 73 Nguyen Hue Street, Vinh Long City 85100, Vietnam
Cong Danh Nguyen Vinh Long Vocational College, Phu Quoi Street, Vinh Long City 85100, Vietnam
Van Thanh Dinh East Asia University of Technology, Trinh Van Bo Street, Hanoi City 12000, Vietnam
Tat Loi Mai Vinh University of Technology Education, 3/2 Street, Vinh City 43109, Vietnam
Manh Cuong Nguyen Thai Nguyen University of Technology, 3/2 Street, Tich Luong Ward, Thai Nguyen City 251750, Vietnam

Volume: 15 | Issue: 6 | Pages: 29354-29361 | December 2025 | https://doi.org/10.48084/etasr.13933

Received: 7 August 2025 | Revised: 13 September 2025 | Accepted: 24 September 2025 | Online: 8 December 2025

Corresponding author: Manh Cuong Nguyen

Abstract

This study presents a multi-objective optimization framework for enhancing the performance of Ultrasonic Vibration-assisted Electrical Discharge Machining (UV-EDM) in processing HARDOX 500 steel. The conflicting objectives of maximizing the Material Removal Rate (MRR) and minimizing the surface roughness (Ra) were simultaneously addressed using the Non-dominated Sorting Genetic Algorithm II (NSGA-II). A set of Pareto-optimal solutions was obtained, representing the trade-offs between machining efficiency and surface integrity. To facilitate the selection of the most suitable solution based on application-specific priorities, the Analytic Hierarchy Process (AHP) was employed to rank the Pareto solutions using assigned weights for MRR and Ra. The integration of AHP into the NSGA-II framework provided an effective decision-support tool for identifying the optimal compromise solution. The experimental validation confirmed the reliability of the predicted results, highlighting the potential of the proposed hybrid approach for optimizing UV-EDM of hard-to-machine materials. Furthermore, under the optimized discharge conditions, the application of ultrasonic vibration increased MRR by 21.65% compared with non-vibration EDM, while Ra increased slightly by 5.81%, remaining within an acceptable machining range. These findings underscore both the reliability of the optimization model and the practical significance of ultrasonic vibration in improving EDM performance.

Keywords:

HARDOX 500, multi-objective optimization, NSGA-II, AHP, surface roughness, material removal rate, decision-making, Ultrasonic Vibration-assisted EDM (UV-EDM)

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