Influence of Process Parameters in n-PMEDM of Inconel 800 with Electrode and Coated Electrodes

Abstract

Abstract. By considering the unique performances, the Powder Mixed Electrical Discharge Machining (PMEDM) mostly encounter choice for machining the hard materials with job features like intricate shapes with grater accuracy and those materials are difficult to cut in conventional machining processes. This Research aimed to prepare parameter index chart for machining nickel based super alloy -Inconel 800 for various requirements. To achieve the aim, In this experimental study on machining of Inconel 800 in PMEDM with electrolyte copper electrode as well as silver coated electrolyte copper electrode is focused. Taguchi full factorial design derived from MINITAB release-16 software was used to design the experimentation. The factors like pulse off time, Current and Pulse on Time were considered. The responses like amount of Tool Wear, Quantity of material removal, surface finishes were noted against each case. In the same experimental conditions the coated electrode increased the MRR by 36.67% with minor increment of maximum surface roughness to 16.11%.

A simple and reliable Taguchi approach for multi-objective optimization to identify optimal process parameters in nano-powder-mixed electrical discharge machining of INCONEL800 with copper electrode

“…To examine the influence of process parameters in n-PMEDM of INCONEL800 with copper electrode, Karunakaran and Chandrsekharan [30] have conducted experiments employing the die sinking CNC EDM machine (Xpert1 model of Electronica India Limited). Use of the low viscosity kerosene as dielectric fluid gets flushed away easily.…”

“…The Taylor-Hobson Surtronic 3 roughness gage (a contact-type surface roughness measuring system) is used for assessing the roughness (from the average of three readings) with 0.8mm cut of length. The full factorial design from MINITAB Release-16 software in [30] demands 27 experiments with three input EDM parameters (viz., gap current, pulse-on-time and pulse-off-time) each having three levels, and found different optimal machining conditions for high MRR and low SR. It is possible to find optimal EDM parameters from 9 experiments using Taguchi's L 9 orthogonal arrays.…”

“…It is possible to find optimal EDM parameters from 9 experiments using Taguchi's L 9 orthogonal arrays. The test data [30] is very much useful to demonstrate the adequacy of Taguchi approach for obtaining the required information through few experiments.…”

“…Extensive experimental work has been carried out to identify the optimum machining parameters for INCONEL materials using EDM [2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12], WEDM [13, 14, 15, 16], VRVEDM [17, 18, 19], Water in EDM [20], Dry EDM [21, 22, 23, 24, 25] and PMEDM [26, 27, 28, 29, 30]. Most of these researchers have utilized the concept of design of experiments.…”

“…Karunakaran and Chandrashekaran [30] have examined the influence of process parameters in PMEDM adopting the Taguchi full factorial design derived from MINITAB Release-16 software with three input parameters each having three levels. They have found different optimal machining conditions for high MRR and low SR.…”