A Novel Satisfaction Function and Distance-Based Approach for Machining Performance Optimization During Electro-Discharge Machining on Super Alloy Inconel 718

Abstract

The present work aims to determine an appropriate setting of process parameters (viz. gap voltage, peak discharge current, pulse-on time, duty factor and flushing pressure) for achieving optimal machining performance during electro-discharge machining of super alloy Inconel 718 by using copper tool electrode. Experiments have been performed based on \(L_{25}\) orthogonal array design of experiment by varying each of the aforesaid process parameter at five different levels. The machining performances have been evaluated in terms of material removal rate, electrode wear rate, surface roughness (\(R_{\mathrm{a}})\), surface crack density, white layer thickness, and micro-hardness of the EDMed Inconel 718 end product. In this paper, a novel optimization route (combining satisfaction function, distance measure approach in conjugation with Taguchi’s philosophy) has been introduced. Application feasibility of the aforementioned approach has been compared to that of obtained through exploration of principal component analysis and combined quality loss concept integrated with Taguchi method. Additionally, morphology of the EDMed work surface of Inconel 718 has been investigated through scanning electron microscopy.