CNC wire-cut EDM input variables analysis on Ni-based superalloy (MONEL K-500)

Wire-cut Electrical Discharge Machining (WEDM) is a notable machining process to produce exact and accurate complex shape products. As a high corrosion resistance with high hardness and strength, Ni-based superalloy (MONEL K-500) is profoundly used in industries like aerospace, marine services, and automobile for applications, such as marine propeller and centrifugal pumps shaft. The process of WEDM is influenced by number of input variables. The proper setting of input variables is essential for accomplishing quality on machined components. In the present investigation, the input variables were pulse on time (T-on), pulse off time (T-off), Gap Voltage (GV), Wire Feed Rate (WFR), and Wire Tension (WT) with five levels considered. The response variables such as Kerf Width (k), Material removal Rate (MRR) and Surface Roughness (R-a) are investigated using Taguchi L-25 orthogonal array and machining responses variables are optimized based on Hybrid Taguchi-Grey Relational Analysis (T-GRA) approach. ANOVA clearly indicates that the T-on, GV and WFR are the foremost influencing input variables on the k, MRR, and R-a. The machined surface morphology is investigated through Scanning Electron Microscope (SEM) at optimum conditions.

Automated summary

WEDM is a significant machining process, with Ni-based superalloy being widely used in industries like aerospace, marine services, and automobile. Proper setting of input variables is crucial for achieving quality on machined components.