Abstract
Wire electrical discharge machining (WEDM) has been, for many years, a precise and efficient non-conventional manufacturing solution in various industrial applications, mostly involving the use of hard-to-machine materials like, among others, the Inconel super alloys. The focus of the present study is on exploring the effect of selected control parameters, including pulse duration, pulse-off time and the dielectric flow pressure on the WEDM process performance characteristics of Inconel 617 material, such as: volumetric material removal rate (MRR), the dimensional accuracy of cutting (reflected by the kerf width) and surface roughness (SR). The research experiment has been designed and carried out using the response surface methodology (RSM) accordingly with the Box–Behnken design scheme. The results of experiments derived in the form of a fitted regression model have been subjected to the analysis of variance (ANOVA) tests. Thus, the variable process parameters and the relevant interactions between them, characterized by a significant influence on the values of the derived output responses, could be explicitly determined.
Highlights
Rapid technological development has recently created a demand for new materials that would have properties enabling their use under harsh operating conditions, including the high temperature, aggressive chemical environment, at variable loads and others
In the Wire electrical discharge machining (WEDM) method, the electrode is usually made of a brass or the other the other alloy, and it is moved by the machine heads, which are steered by the CNC controller
Statistical and mathematical techniques available under the response surface methodology (RSM) approach have been used to determine the correlations between the measured output responses and accepted independent process parameters
Summary
Rapid technological development has recently created a demand for new materials that would have properties enabling their use under harsh operating conditions, including the high temperature, aggressive chemical environment, at variable loads and others Conditions of such a nature occur, inter alia, in gas turbines, nuclear reactors, power generators equipment or chemical industry installations [1]. One such material is an alloy based on nickel and chromium, which contains other elements such as: niobium, iron, aluminum [2], commercially termed as “Inconel”. This is due to high content of abrasive particles in this alloy, its low thermal and electrical conductivity, high tendency to welding to the tool, and forming built-up edges, etc. [1,2]
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