Experimental investigations on electrical discharge machining of inconel

Abstract

This work presents the optimization while machining of Inconel 800HT super alloy as base material and copper as the electrode using ZNC Electrical Discharge Machine with positive polarity Formation of complex shapes by this material alloy with reasonable speed and surface finish is not an easy task with the traditional machining More over the edge profile which is circular in this work formed by the energy released by the spark does not result with expected profile After machining it is observed that the edge of the profile gets disintegrated because of which the material will lose its fatigue strength Central Composite Design of Response Surface Methodology is used with 6 blocks for the analysis For experimentation Peak Voltage Vin Peak Current Iin and Pulse on Time TON are taken as key input parameters based on literature support MRR Metal Removal Rate SR Surface Roughness TWR Tool Wear Rate Edge Disintegration or OC Over Cut has been taken as performance measures Then the response surface methodology RSM is employed over the input parameters to get the suitable mathematical model and the outcome reveals that the suggested model helps to predict the factor values within the limit of investigation At 95 level of confidence the results show that the input current value has the greatest influence on the disintegration factor followed by the input voltage and then spark on time on the MRR and OC of measurements It is observed that almost near optimal is observed at Voltage level of 1 V Current value of 17 Amps and OnTime of 850 and#956;sec The desirability is 0 489 for MRR 0 703 for TWR 0 649 for SR and 0 649 for OC at the optimal setting of the parameters Finally Non Sorting Genetic Algorithm is utilized for optimization of multiple responses. newline