Abstract

The properties of the Inconel 718 super alloy are used in the manufacturing of aircraft components, due to high hardness and toughness machining of such alloy by conventional machining process is difficult. To overcome this, nonconventional techniques are used, from which electrochemical machining (ECM) is good alternative. Electrochemical Machining (ECM) is a nonconventional manufacturing process widely employed in various industries due to its precision in shaping complex, detailed components. This study focuses on exploring and optimizing the key machining parameters in ECM to enhance machining efficiency and surface finish quality of Inconel 718. The research methodology involves a systematic experimental investigation, employing a series of controlled tests on an ECM machine. The controllable process parameters selected which are current, voltage and duty cycle. The aim is to comprehend the nuanced influence of these variables on material removal rate (MRR) and overcut and to investigate optimum level of process parameter. The analysis shows that the duty cycle and current are most influencing factor for controlling depth of overcut and for improving MRR, but excessive high duty cycle can be counterproductive which results in increased heat generation because continuous current flow generates heat in the electrolyte and work piece.

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