RSM-VIKOR Based Optimization of Machining Parameters for Improved Surface Integrity of HEAs

¹ Department of Mechanical Engineering, P V P Siddhartha Institute of Technology, Vijayawada. India
² Department of Mechanical Engineering, P V P Siddhartha Institute of Technology, Vijayawada. India.
³ Professional trainer, Saudi Electrical Services Polytechnic, Ras Tanura, Saudi Arabia.
⁴ Department of Electronics and Communication Engineering, Sri Venkateshwara College of Engineering, Bengaluru - 562157.
⁵ Department of Electrical and Electronics Engineering, Academy of Maritime Education and Training (AMET) Deemed University, East Coast Road, Kanathur, Chennai
⁶ Department of Mechanical Engineering, Saveetha School of Engineering, SIMATS, Saveetha University, Chennai 602105, Tamil Nadu, India.

^* Corresponding author: This email address is being protected from spambots. You need JavaScript enabled to view it.

Published online: 29 May 2026

Abstract

This work employed Response Surface Methodology (RSM) with the VIKOR multi-criteria decision-making model to investigate the machining performance of the high-entropy alloy (HEA) in ECM method. Three electrolyte systems were employed such as sodium nitrate (NaNO₃), sodium chloride (NaCl) and NaNO₃/NaCl mixed electrolyte. The tests were conducted by varying the feed rate (0.4–0.6 mm/min) and electrolyte concentration (100–200 g/L). The MRR model was found to be significant (p = 0.03814) by most significant parameters, electrolyte type and concentration. Feed rate (p = 0.03166) and electrolyte type (p = 0.01301) also influenced surface roughness respectively. Perturbation analysis has shown that the type of electrolyte is the most influential factor for increasing MRR and reducing SR. Multi-objective optimization using the RSM-VIKOR method identified the optimal factors at EC = 100 g/L, mixed electrolyte (NaNO₃ + NaCl), and feed rate of 0.5 mm/min, yielding a high MRR of 67.3 rnmVmin and a minimum SR of 1.26 μm. The results demonstrate the effectiveness of the hybrid RSM-VIKOR approach in resolving performance and enhancing ECM efficiency for HEAs.