a b s t r a c tIn the present study a multi response optimization method using utility concept is proposed for wire electrical discharge machining (WEDM) of Nimonic-80A alloy. The machining characteristics that are being investigated are material removal rate (MRR) and surface roughness (SR) along with surface topography of the machined surface. The study makes use of experimentation planned and executed as per Taguchi's robust design methodology. The Investigation indicated that material removal rate and surface roughness increases with increase in pulse-on time and decreases with increase in pulse-off time. Significant interactions have been found between pulse-on time (T on ) and pulse-off time (T off ), pulse-on time (T on ) and peak current (IP), pulse-off time (T off ) and peak current (IP) for material removal rate; and pulse-on time (T on ) and peak current (IP) for surface roughness. Multi-response optimization with utility concept provides the collective optimization of both responses for improving the mean of the process.
Nimonic-80A is a nickel based super alloy which is specifically used in aerospace industry for its high strength to weight ratio and corrosion resistance. This paper presents the influence of process parameters of wire cut Electrical Discharge Machining (WEDM) during the machining of Nimonic 80A with brass wire as electrode and optimization of machining parameters on kerf width. Process parameters (pulse-on time, pulse-off time, peak current, spark gap set voltage, wire feed and wire tension) have been investigated using L27orthogonal array. With the assistance of Taguchi quality design, ANOVA and F-test, significant parameters affecting the kerf have been identified. The surface topography of machined samples has been studied in correlation with the rate of input energy into the spark.
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