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This paper aims to investigate the influence of “BroncoCut-X” (copper core-ZnCu50 coating) electrode on the machining of Ti-3Al-2.5V in view of its extensive use in aerospace and medical applications. The machining parameters are selected as Spark-off Time (ST_off), Spark-on Time (ST_on), Wire-speed (S_w), Wire-Tension (WT) and Servo-Voltage (S_v) to explore the machining outcomes. The response characteristics are measured in terms of material removal rate (MRR), average kerf width (KW) and average-surface roughness (SA).

Taguchi’s approach is used to design the experiment. The “AC Progress V2 high precision CNC-WEDM” is used to conduct the experiments with ϕ 0.25 mm diameter wire electrode. The machining performance characteristics are examined using main effect plots and analysis of variance. The grey-relation analysis and fuzzy interference system techniques have been developed to combine (called grey-fuzzy reasoning grade) the experimental response while Rao-Algorithm is used to calculate the optimal performance.

The hybrid optimization result is obtained as ST_off = 50µs, ST_on = 105µs, S_w = 7 m/min, WT = 12N and S_v=20V. Additionally, the result is compared with the firefly algorithm and improved gray-wolf optimizer to check the efficacy of the intended approach. The confirmatory test has been further conducted to verify optimization results and recorded 8.14% overall machinability enhancement. Moreover, the scanning electron microscopy analysis further demonstrated effectiveness in the WEDMed surface with a maximum 4.32 µm recast layer.

The adopted methodology helped to attain the highest machinability level. To the best of the authors’ knowledge, this work is the first investigation within the considered parametric range and adopted optimization technique for Ti-3Al-2.5V using the wire-electro discharge machining.

The goal of this study is to determine the values of the process parameters that should be used during the machining of ceramic tile using the abrasive water jet (AWJ) process in order to achieve the lowest possible values for surface roughness and kerf taper angle.

In the present work, ceramic tile is processed by the AWJ process and experimental data were recorded using the RSM approach based Box–Behnken design matrix. The input process factors were water jet pressure, jet traverse speed, abrasive flow rate and standoff distance, to determine the surface roughness and kerf taper angle. ANOVA was used to check the adequacy of model and significance of process parameters. Further, the elite opposition-based learning grasshopper optimization (EOBL-GOA) algorithm was implemented to identify the simultaneous optimization of multiple responses of surface roughness and kerf taper angle in AWJ.

The suggested EOBL-GOA algorithm is suitable for AWJ of ceramic tile, as evidenced by the error rate of ±2 percent between experimental and predicted solutions. The surfaces were evaluated with an SEM to assess the quality of the surface generated with the optimal settings. As compared with initial setting of the SEM image, it was noticed that the bottom cut surface was nearly smooth, with less cracks, striations and pits in the improved optimal results of the SEM image. The results of the analysis can be used to control machining parameters and increase the accuracy of AWJed components.

The findings of this study present an innovative method for assessing the characteristics of the nontraditional machining processes that are most suited for use in industrial and commercial applications.

Exact solution of time–cost trade-off problem (TCTP) by the state-of-the-art meta-heuristic algorithms can be obtained for small- and medium-scale problems, while satisfactory results cannot be obtained for large construction projects. In this study, a hybrid heuristic meta-heuristic algorithm that adapts the search domain is developed to solve the large-scale discrete TCTP more efficiently.

Minimum cost slope–based heuristic network analysis algorithm (NAA), which eliminates the unfeasible search domain, is embedded into differential evolution meta-heuristic algorithm. Heuristic NAA narrows the search domain at the initial phase of the optimization. Moreover, activities with float durations higher than the predetermined threshold value are eliminated and then the meta-heuristic algorithm starts and searches the global optimum through the narrowed search space. However, narrowing the search space may increase the probability of obtaining a local optimum. Therefore, adaptive search domain approach is employed to make reintroduction of the eliminated activities to the design variable set possible, which reduces the possibility of converging into local minima.

The developed algorithm is compared with plain meta-heuristic algorithm with two separate analyses. In the first analysis, both algorithms have the same computational demand, and in the latter analysis, the meta-heuristic algorithm has fivefold computational demand. The tests on case study problems reveal that the developed algorithm presents lower total project costs according to the dependent t-test for paired samples with α = 0.0005.

In this study, TCTP is solved without considering quality or restrictions on the resources.

The proposed method enables to adapt the number of parameters, that is, the search domain and provides the opportunity of obtaining significant improvements on the meta-heuristic algorithms for other engineering optimization problems, which is the theoretical contribution of this study. The proposed approach reduces the total construction cost of the large-scale projects, which can be the practical benefit of this study.