Optimization of EDM process parameters for TWR on machining of Inconel 600 superalloy using Taguchi approach

Abstract

Electrical discharge machining (EDM) is a non-traditional machining technique that is commonly employed on hard materials. The fact that EDM can cut any conductivematerial, independently of its hardness, has made it popular. EDM is extensively used to shape or create advanced technological materials which are used in extreme conditions. The effects of input parameters on the effective machining of Inconel 600 superalloy was investigated in this study. The tool electrode was made of Tungsten Carbide (WC), and the dielectric fluid was EDM oil. The Taguchi method was used to investigate the effects of control factors including pulse-on-time (Ton), peak current (Ip), and gap voltage (Vg) on the performance criterion TWR. Using an orthogonal array (OA) L9, the research were carried out at three levels. The EDM performance aspects were investigated using the signal-to-noise ratio and ANOVA. The Taguchi technique was used to optimize the input and output parameters using the statistical software MINITAB-17. During the EDM process, TWR grows somewhat linearly with increasing Ip. TWR reduces as Vg increases, then increases as Vg increases. TWR increases with increasing Ton and then drops with increasing Ton. The tool wear rate is lowest at the first level of Ip, the second level of Vg, and the third level of Ton. ANOVA revealed that Ip, Vg, and Ton all had a significant influence on TWR. Obtained optimum input variables value for tool wear rate are Ip (30 A), Vg (94 V), and Ton (150 s). The predicted ideal range of TWR at 95% confidence level was confirmed by conducting confirmation experiments, wherein the TWR was achieved as 0.551 mm3/min. To validate Taguchi's optimization approach, confirmation tests were performed using optimal values of input parameters.