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Multi-objective optimization of wire-EDM of Inconel 625 by using desirability function approach

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Abstract

Wire electro-discharge machining (Wire-EDM) is one of the most versatile and efficient manufacturing process to machine difficult-to-cut materials. In this experiment, wire-EDM of Inconel 625 work piece material is performed by using zinc coated brass wire as wire electrode and distilled water as dielectric fluid. Input parameters taken during experimentation are pulse-on-time (Ton), pulse-off-time (Toff), and servo voltage (Sv). Here, experiments are conducted as per Taguchi’s experimental design i.e. L9 orthogonal array to study the effect of machining parameters on the output responses. To access the machining performance of the wire-EDM process during machining of Inconel 625, the output responses considered are material removal rate (MRR), kerf width (Kw), and average surface roughness (Ra) of the machined surface. For multi-objective optimization of these output responses during the wire-EDM process, desirability function approach is used to achieve better machining performance i.e. higher MRR, lower Kw and lower Ra. The optimum parametric setting for better machining performance is obtained to be Ton = 18 µm, Toff = 53 µm, Sv = 23 V. Also, analysis of variance (ANOVA) is performed to study the influence of machining parameters on the overall output performance (composite desirability). Here, pulse-on-time is found to be the highest significant factor with percentage contribution of 64.14% for composite desirability.

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Abbreviations

ANOVA:

Analysis of variance

Ra :

Average surface roughness

DFA:

Desirability function approach

Kw :

Kerf width

MRR:

Material removal rate

Ton :

Pulse-on-time

Toff :

Pulse-off-time

Sv :

Servo voltage

wire-EDM:

Wire electro-discharge machining

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Authors and Affiliations

  1. Department of Mechanical Engineering, Centre for Advanced Post Graduate Studies, Biju Patnaik University of Technology, Rourkela, Odisha, India

    Swastik Kumar Kar, Pradeep Kumar Mishra & Anshuman Kumar Sahu

  2. Department of Mechanical Engineering, National Institute of Technology Rourkela, Rourkela, Odisha, India

    Siba Sankar Mahapatra

  3. Department of Mechanical Engineering, Chouksey Engineering College, Bilaspur, Chhattisgarh, India

    Joji Thomas

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  1. Swastik Kumar Kar
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Correspondence to Anshuman Kumar Sahu.

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Kar, S.K., Mishra, P.K., Sahu, A.K. et al. Multi-objective optimization of wire-EDM of Inconel 625 by using desirability function approach. Int J Interact Des Manuf 17, 931–938 (2023). https://doi.org/10.1007/s12008-022-01184-6

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