Parameter Optimization of Wire-Cut EDM on Inconel Alloy for Maximizing Material Removal Rate †

Abstract

In the existing investigation, the influence of wire-cut electrical discharge machining (WEDM) input factors such as pulse-on time, pulse-off time, wire tension, and taper angle on the material removal rate (MRR) on Inconel 825 was investigated. Experimental trials were performed according to the central composite design (CCD). An ANOVA test was conducted to evaluate the influence of the most significant WEDM process input parameter. The optimization of the response was achieved using the desirability approach to attain the maximum MRR. The optimum setting conditions were obtained as Ton of 0.8 µs, Toff of 38 µs, wire tension of 14 N, and taper angle of 2° for the MRR value of 2.98 g/min with a desirability of 1. Finally, the 3D surface plots were used to illustrate the variations of the output response with respect to input parameters.