Abstract
Micro-Electric Discharge Machining (μ-EDM) is one of the widely applied micromanufacturing processes. However, it has several limitations, such as a low cutting rate, difficult debris removal, and poor surface integrity, etc. Hybridization of the μ-EDM is proposed as an alternative to overcome the process limitations. Conversely, it complicates the process nature and poses a challenge for modelling and predicting critical process responses. Therefore, in this work, two distinct, nonparametric, previously unreported, workpiece material independent models using a Generalized Regression Neural Network (GRNN) and Gaussian Process Regression (GPR) were developed and compared to assess their performance with limited training data. Various smoothing factors and kernels were tested for GRNN and GPR, respectively. The prediction of models was compared in terms of the mean absolute percentage error, root mean square error, and coefficient of determination. The results showed that GPR outperforms GRNN and accurately predicts the μ-EDM process responses. The GRNN’s performance was better for less stochastic output with a discernible pattern than other outputs. The Automatic Relevance Determination (ARD) squared exponential kernel was found to be the best performing kernel among those chosen. GPR models can be used with reasonable accuracy to predetermine critical process outputs as they have R2 values above 0.90 for both training and validation data for all outputs. This work paves the way for future industrial implementation of GPR to model and predict the outputs of complex hybrid machining processes.