Wire EDM cutting of Inconel 718 nickel-based superalloy: kerf and MRR analysis

Abstract

PurposeInconel 718 (IN718) is a high-performance nickel-based superalloy with high oxidation-corrosion-temperature resistance, high strength (tensile, fatigue, creep and rupture), durability, toughness, hardness and dimensional stability, which is difficult to machine with traditional fabrication methods. To overcome these difficulties, wire electrical discharge machining (WEDM), one of the modern manufacturing methods, is used.Design/methodology/approachMain performance criteria in WEDM; material removal rate (MRR), cutting speed, surface roughness, cutting width (kerf) and wire wear rate. In this study, the effect of processing parameters on kerf and MRR because of processing IN718 in WEDM was investigated. Machining parameters, voltage, wire feed rate and dielectric fluid pressure were determined. Deionized water was used as a dielectric fluid and 0.3 mm brass wire was used as wire in the experiments. Gray Relational Analysis (GRA), which is one of the multi-criteria decision-making methods, has been applied for the optimization of the machining parameters in the cutting process with the WEDM. Analysis of variance (ANOVA) was used to determine the effect percentages of the cut-off parameters.FindingsThe parameter with the highest effect was determined as tension with a rate of 76.95% for kerf and 91.21% for MRR.Originality/valueThe novel approach uses Taguchi-based GRA optimization as a result of cutting IN718 with WEDM, reducing cost and time consumption.

Evaluating the optimum abrasive water jet machinability for CARALL composites with various fiber orientations

“…After determining the drilling parameters and levels, the appropriate orthogonal design (L18) and the quality characteristics, the relationships between the control factors/drilling parameters and the quality characteristics were realized by applying the steps of the TEDM as follows (Figure 3). 14,35,40–44 …”

“…After determining the drilling parameters and levels, the appropriate orthogonal design (L18) and the quality characteristics, the relationships between the control factors/drilling parameters and the quality characteristics were realized by applying the steps of the TEDM as follows (Figure 3). 14,35,[40][41][42][43][44] The TEDM can only optimize a single response and cannot optimize more than one response at the same time. Most of the problems that arise in industrial applications are multi-criteria in nature, so that making a decision based on only one evaluation criterion often makes no sense.…”

Wire-EDM performance and surface integrity of Inconel 718 with unique microstructural features fabricated by laser powder bed fusion

“…They found that with the decrease in wire electrode diameter, cutting precision increased, and wire and workpiece waste decreased, resulting in lower environmental impacts, reduction in craters on the machined surfaces, reduction in microhardness change, and reduction in recast layer thickness value. Karataş [27] machined Inconel 718 alloy via the WEDM method, considering changes in MRR and kerf by process parameters using gray relational analysis (GRA) and analysis of variance (ANOVA) methods. It was concluded that wire tension significantly affected the MRR while the effect of dielectric fluid pressure was insignificant.…”

Wire-EDM performance and surface integrity of Inconel 718 with unique microstructural features fabricated by laser powder bed fusion

“…They found that with the decrease in wire electrode diameter, cutting precision increased, and wire and workpiece waste decreased, resulting in lower environmental impacts, reduction in craters on the machined surfaces, reduction in microhardness change, and reduction in recast layer thickness value. Karataş [25] machined Inconel 718 alloy via the WEDM method considering changes in MRR and kerf by process parameters using Gray Relational Analysis (GRA) and Analysis of variance (ANOVA) methods. It was concluded that wire tension signi cantly affected the MRR while the effect of dielectric uid pressure was insigni cant.…”