Abstract

ABSTRACT Non-conventional machining processes are the requirements of the fastest growing industries because of the precision, complex, intricate shape of the work material, higher tolerances and economically. WEDM is a variation and development of EDM and a spark erosion process in which the material revioval takes place due to erosion caused by electrical sparks. This process is utilized for machining of conductive and difficult-to- machine material irrespective of hardness with the help of thin wire electrode. This research aims to examine the influence of Wire Electro-discharge Machining (WEDM) parameters on surface roughness (SR) and cutting speed to improve the productivity with a high surface finish of Ni-based super alloy namely Inconel 600 wrought super alloy. In this experimental work, the hybrid optimization has been done for the machining of Ni-based wrought Inconel-600 super alloy using standard brass wire. The peak current (IP), taper angle, pulse on Time (Ton), a pulse of time (Toff) and die-electric fluid pressure had selected as operation constraints to conduct experimental trials. The cutting rate and surface roughness (SR) were considered as output responses. The experimental outcomes were optimized by Gray relational analysis coupled with a Taguchi hybrid optimization method. The optimized parameters by multi-parametric optimization method showed the considerable improvement in the process and will facilitate the WEDM industries to improve the productivity with a higher surface finish.

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