Parametric modeling and optimization for wire electrical discharge machining of Inconel 718 using response surface methodology

  • Aggarwal V
  • Khangura S
  • Garg R
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Inconel 718 is a high-nickel-content superalloy which possesses
excellent strength at elevated temperatures and resistance to oxidation
and corrosion. This alloy has wide applications in the manufacturing of
aircraft engine parts such as turbine disks, blades, combustors and
casings, extrusion dies and containers, and hot work tools and dies, but
the inherent problems in machining of superalloys with conventional
techniques necessitate the use of alternative machining processes. The
wire electrical discharge machining (WEDM) process has been recently
explored as a good alternative of conventional machining methods, but
there is lack of data and suitable models for predicting the performance
of WEDM process particularly for Inconel 718. In the present work,
empirical modeling of process parameters of the WEDM has been carried
out for Inconel 718 using a well-known experimental design approach
called response surface methodology. The parameters such as pulse-on
time, pulse-off time, peak current, spark gap voltage, wire feed rate,
and wire tension have been selected as input variables keeping others
constant. The performance has been measured in terms of cutting rate and
surface roughness. The models developed are found to be reliable
representatives of the experimental results with prediction errors less
than +/- 5 %. The optimized values of cutting rate and surface
roughness achieved through multi-response optimization are 2.55 mm/min
and 2.54 mu m, respectively.

Author-supplied keywords

  • Cutting rate
  • Inconel 718
  • Response surface methodology
  • Surface roughness
  • Wire electrical discharge machining

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  • Vivek Aggarwal

  • Sehijpal Singh Khangura

  • R. K. Garg

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