Abstract
Monel K-500, a nickel–copper based alloy, is a very hard and tough material. Machining of such hard and tough materials always becomes a challenge for industry and this has been resolved by wire electric discharge machining (WEDM), a popular non-conventional machining method used for machining tough and hard materials having complex shapes. For the first time reported in this present research work is an experimental investigation executed on Ni-27Cu-3.15Al-2Fe-1.5Mn based superalloy using WEDM to model cutting rate (CR) and surface roughness (SR) using response surface methodology (RSM). The process parameters have been selected as pulse-on time, pulse-off time, spark-gap voltage and wire-feed rate. Experiments have been planned according to the central composite design (CCD). The results show that pulse-on time has a direct effect on CR while the pulse-off time has a reverse effect. The CR increases as pulse-on time increases, and decreases as pulse-off time increases. SR increases as pulse-on time increases, and decreases as pulse-off time increases. Furthermore, increase in spark-gap voltage decreases CR and SR both. The wire feed-rate has a negligible effect for both the response parameters. The optimized values of CR and SR achieved through multi-response optimization are 2.48 mm/min and 2.12 µm, respectively.
Highlights
Jet engines, gas turbines and rocket applications require materials that possess high corrosion, creep, oxidation resistance and fatigue strength at temperatures above 1100 ◦ C
Therotates servo according to the signal oftomicrocontroller and, this motion isthis transmitted the work motor rotates according the signal of microcontroller and, motion is to transmitted table executing theexecuting machining work being work done being on wire electric discharge machining (WEDM)
(36 volt) value indicated the higher cutting rate (CR) (2.5 mm/min). This is due to the fact that as the servo voltage phenomenon has been observed as servo voltage decreases, the CR increases due to less gap among tool and work leading to more melting and evaporation of work piece
Summary
Gas turbines and rocket applications require materials that possess high corrosion, creep, oxidation resistance and fatigue strength at temperatures above 1100 ◦ C. The nickel-based alloys are much tougher and stronger in contrast to iron and cobalt-based alloys due to their outstanding mechanical properties, and resistance to creep at elevated temperatures Attributable to these reasons, nickel-based superalloys are of high importance and commonly used in industry [3]. Modelled a process of WEDM by applying the Taguchi method to examine the impact of pulse-on time (Ton), pulse-off time (Toff), and WT (Wire Tension) upon the cutting rate (CR) and surface roughness (SR). Mandal et al [20] applied a central composite rotatable design of response surface methodology (RSM) during cutting of Nimonic C-263 with WEDM for investigating the effect of Ton, Toff, SV and flow rate of dielectric on CR, SR, and wire wear ratio.
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Free) 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a call
