Modelling and Analysis of the Effect of EDM-Drilling Parameters on the Machining Performance of Inconel 718 Using the RSM and ANNs Methods

Abstract

Electrical Discharge Machining (EDM) is one of the most efficient processes to produce high-ratio micro holes in difficult-to-cut materials in the Inconel 718 superalloy. It is important to apply a statistical technique that guarantees a high fit between the predicted values and those measured during analysis of test results. It was especially important to check which method gives a better fit of the calculated result values in case they were relatively small and/or close to each other. This study developed models with the use of the response surface methodology (RSM) and artificial neural networks (ANNs). The aim of the study was comparison between two models (RSM and ANNs) and to check which model gives a better data fit for relatively similar values in individual tests. In all cases, the neural network models provided a better value fit. This is due to the fact that neural networks use better fitted functions than in the case of the RSM method using quadratic fitting. This comparison included the aspect ratio hole and the thickness side gap data, the values of which for individual tests were very similar. The paper reports an analysis of the impact of parameter variables on the analyzed factors. Higher values of current amplitude, pulse time length, and rotational speed of the working electrode resulted in higher drilling speed (above 15 µm/s, lower linear tool wear (below 15%), higher aspect ratio hole (above 26), lower hole conicity (below 0.005), and lower side gap thickness at the hole inlet (below 100 µm).

Analysis of the end-of-life the front suspension beam of a vehicle

“…In view of contact between the mating surfaces, which are influenced by the degree of isotropy, wear may be intermittent or continuous [14]. Given a small degree of isotropy, the ridges of the irregularities move on one another, and given a high degree of isotropy, the ridges of microirregularities rest on one another or find their way into the cavities, ridge the opposite surface or become shorn [13]. In the latter case, there will be more wear products and the surfaces may demonstrate lower wear resistance.…”

Influence of Silver-Coated Tool Electrode on Electrochemical Micromachining of Incoloy 825

“…The degree of straightness of the through-hole that is machined is called conicity (CY) and it can be calculated using Equation ( 4) [42][43][44]:…”

Study of Correlation of Machining Performance and Geometrical Tolerances of Si3N4-TiN Composites Using EDM Process

“…According to Shahid Machno M et al [29], the thickness of the recast layer increased when the discharge current was intensi ed. The worn surface was present around the cavity's perimeter and was caused by an increase in spark energy [30][31][32][33].…”