Optimization of WEDM process parameters in machining Nimonic 75 alloy using brass wire

Abstract

PurposeAn experimental study has been conducted to model and optimize wire electric discharge machining (WEDM) process parameters such as pulse-on time, pulse-off time, servo voltage and peak current for response characteristics during machining of Nimonic 75 alloy.Design/methodology/approachThe response surface methodology (RSM)-based Box–Behnken's design has been employed for experimental investigation. RSM is used for developing quadratic regression models for selected response variables i.e. material removal efficiency and kerf width. To validate the model, confirmation experiments have been performed. The multi-response optimization has been done using desirability function approach.FindingsThrough analysis of variation, the percent contribution of process parameters on the response characteristics has been found. Pulse-off time is the most significant parameter affecting the kerf width and material removal efficiency followed by pulse-on time. The quadratic regression models have been developed for prediction of selected response variables. An attempt has been made to optimize the WEDM parameters for material removal efficiency and kerf width. The recommended process parameter setting for maximum material removal efficiency and minimum kerf width have been found to be pulse-on time = 0.6 µs, pulse-off time = 14 µs, servo voltage = 25 V and peak current = 200 A.Originality/valueThe “kerf width” is an important response variable for maintaining dimensional accuracy of the machined component, but has not been given due attention by the researchers. In the present work, the developed regression model for “kerf width” can be used in estimating wire offset setting and thereby getting a dimensionally accurate product. The optimum process parameters obtained in WEDM of Nimonic 75 alloy will contribute in database of machining. The outcome of this study would be added to scare database of the machining of Nimonic 75 alloy and also would be extremely useful for making the technology charts for WEDM.