Machinability of nickel based alloys using electrical discharge machining process

Abstract

The high temperature materials such as nickel based alloys and austenitic steel are frequently used for manufacturing critical aero engine turbine components. Literature on conventional and unconventional machining of steel materials is abundant over the past three decades. However the machining studies on superalloy is still a challenging task due to its inherent property and quality. Thus this material is difficult to be cut in conventional processes. Study on unconventional machining process for nickel alloys is focused in this proposed research. Inconel718 and Monel 400 are the two different candidate materials used for electrical discharge machining (EDM) process. Investigation is to prepare a blind hole using copper electrode of 6mm diameter. Electrical parameters are varied to produce plasma spark for diffusion process and machining time is made constant to calculate the experimental results of both the material. Influence of process parameters on tool wear mechanism and material removal are considered from the proposed experimental design. While machining the tool has prone to discharge more materials due to production of high energy plasma spark and eddy current effect. The surface morphology of the machined surface were observed with high resolution FE SEM. Fused electrode found to be a spherical structure over the machined surface as clumps. Surface roughness were also measured with surface profile using profilometer. It is confirmed that there is no deviation and precise roundness of drilling is maintained.