Analysis of Dimensional Accuracy (Over Cut) and Surface Quality (Roughness) in Electrical Discharge Machining of Inconel-718 Alloy

Abstract

Inconel-718 is a nickel based super alloy (difficult-to-cut material) used in aerospace industry. Analysis of machining performances viz. Over Cut (OC) & Surface Roughness (SR) for Inconel-718 through rotary Cu-pin tool electrode have been carried out. Peak current (Ip), pulse-on time (Ton), tool rotation (Nt) & hole depth (h) were used as input factors in Electrical Discharge Drilling (EDD) of Inconel-718 work-piece. Effect of input parameters on performance characteristics like OC & SR were found by Taguchi’s L9 (34) orthogonal array. It is reveals that Ip & h are most affecting factors that affects OC & SR. The Scanning Electron Microscope image was used to measure diameter of hole on work-piece after machining.

Scanning Electron Microcopy Analysis after Electrical Discharge Machining of Advanced Ni-Based Alloy

“…The present study was chosen after considering the following criteria, namely the number of factors and their levels. Accordingly, experimentation was performed based on L18 (2 1 × 3 5 ), with six columns and eighteen rows. The authors suggest that Taguchi's technique is a useful tool to conduct the experiment, which reduces the time and cost of the machining process [12,13].…”

“…Researchers investigate the machinability of nickel-based superalloys using EDM. The authors analyze the surface integrity and microstructure, such as the machined surface, including the formation white/recast layer [5]. The stimulus of changed process parameters on the white layer thickness was studied, providing insights into optimizing the machining parameters for enhanced EDM performance [6].…”