Optimization of Material Removal Rate and Wear Rate in EDM Machining of Inconel 625 Using a Novel Nano Al-Ni Composite Electrode: A Response Surface Methodology Approach
J. Environ. Nanotechnol., Volume 13, No 3 (2024) pp. 14-24
Abstract
The electric discharge machine is a novel machining technique. When the tool and the work item do not communicate. Components composed of difficult-to-machine hard materials. In the current experimental inquiry, the process factors that influence the machining concert process and its effectiveness are explored. The response table for each set of machining limitations is used in conjunction with the response surface methodology in the research to determine the appropriate levels of machining factors. The work's machining input parameters are optimized for maximum material removal rate (MRR) and reduce the electrode wear rate (EWR) when electro-discharge machining Inconel 625 using the tool Nano Al-Ni composite electrode. Another analysis of variance is to identify the factors causing the different answers mentioned above. EDAX was also used to investigate the material composition of the workpiece. Machined workpiece surfaces were evaluated using scanning electron microscopy to assess surface accuracy and microstructural characteristics (SEM). The following conclusions may be drawn from this work. The MRR parameter that is most affected is pulse off time. As pulse-off time lengthens, MRR increases. According to the response graph, the greatest MRR value that can be attained under the ideal parameters of Ip = 8A, T-ON = 50μs, and T-OFF= 100μs is 0.0115 g/min. The magnitudes of MRR range from 0.0091 to 0.044 g/min. Impact of T ON and T OFF: Higher EWR is 0.0022 g/min is seen in runs with T ON = 70 μs and T OFF = 100 μs.
Full Text
Reference
Deepanraj, B., Senthilkumar, N., Ranjitha, J., Jayaraj, S., and Ong, H.C., Biogas from food waste through anaerobic digestion: optimization with response surface methodology, Biomass Convers Biorefin, 11 (2), 227–239 (2021).
https://doi.org/10.1007/s13399-020-00646-9
Dhanabalan, S., Sivakumar, K. and Sathiya Narayanan, C., Analysis of Form Tolerances in Electrical Discharge Machining Process for Inconel 718 and 625, Mater. Manuf. Processes, 29(3), 253–259 (2014).
https://doi.org/10.1080/10426914.2013.852213
Goyal, A., Pandey, A., Sharma, P., and Sharma, S.K., Study on Ni-based super alloyusing cryogenic treated electrode by Taguchi methodology, Mater Today Proc., 4 (2), 2068–2076 (2017).
https://doi.org/10.1016/j.matpr.2017.02.052
Jeykrishnan, J., Vijaya Ramnath, B., Akilesh, S. and Pradeep, K. R. P., Optimization of process parameters on EN24 Tool steel using Taguchi technique in Electro-Discharge Machining (EDM), IOP Conf. Ser. Mater. Sci. Eng., 149 012022 (2016).
https://doi.org/10.1088/1757-899X/149/1/012022
Justin, R. Y., Bovas, H. B. A., Raj, K. S. and Balamurugan, G. M., Influence of Novel Al-Ni Electrodes on Roughness and Machining Time in Inconel 625 EDM Machining: A Comprehensive RSM Performance Analysis, J. Environ. Nanotechnol., 13(1), 243–253 (2024b),
https://doi.org/10.13074/jent.2024.03.241547
Karbasian, A., Shirazi, M. and Mahmoudi, A. H., Effect of Surface Roughness on Brinell Hardness and Load-Displacement Curves using a Macro Indentation, International Journal of Engineering, 914–924 (2023).
https://doi.org/10.5829/IJE.2023.36.05B.08
Kumar, V., Parametric Optimization of Material Removal Rate of EDM (AISI-4147) by using Taguchi Approach, Journal of University of Shanghai for Science and Technology, 24 (03), 151–159 (2022).
https://doi.org/10.51201/JUSST/22/0265
Kundu, B., Samanta, S., Ghosh, D., Saha, K., Ghosh, S. and Paul, T., Optimisation of process parameters for Inconel 718 Spur gear, Mater. Today Proc., 80 1477–1481 (2023).
https://doi.org/10.1016/j.matpr.2023.01.281
Mathew, P. D., Saif, M. and Zishan, M., Optimization of wire-EDM process of titanium alloy-Grade 5 using Taguchi’s method and grey relational analysis, Mater. Today Proc., 72 144–153 (2023).
https://doi.org/10.1016/j.matpr.2022.06.376
Payal, H., Fekadu, E., Bhattacharya, A., Priyadarshini, S. and Mishra, A., Optimization of machining parameters in EDM of Inconel 625 using Taguchi approach, Mater. Today Proc., 80, 1422–1428 (2023).
https://doi.org/10.1016/j.matpr.2023.01.223
Phan, N. H., Van Dong, P., Dung, H. T., Van, T. N., Muthuramalingam, T., Shirguppikar, S., Tam, N. C. and Ly, N.T., Multi-object optimization of EDM by Taguchi-DEAR method using AlCrNi coated electrode, Int. J. Adv. Manuf. Technol., 116 (5–6), 1429–1435 (2021).
https://doi.org/10.1007/s00170-021-07032-3
Raj, Y. J., Bejaxhin, A. B. H. and Rajkumar, S., Review about removal rates and wear rate of EDM using Nano composite electrodes with variant electrolytic solutions, AIP Conference Proceedings (2024a).
http://dx.doi.org/10.1063/5.0197422GARG
Sharma, D., Bhowmick, A. and Goyal, A., Enhancing EDM performance characteristics of Inconel 625 superalloy using response surface methodology and ANFIS integrated approach, CIRP J. Manuf. Sci. Technol., 37, 155–173 (2022a).
https://doi.org/10.1016/j.cirpj.2022.01.005
Sharma, S., Kumar Vates, U. and Bansal, A., Parametric optimization in wire EDM of D2 tool steel using Taguchi method, Mater Today Proc, 45 757–763 (2021).
