Skip to main content
SpringerLink
Log in

Mathematical modeling and analysis of WEDM machining parameters of nickel-based super alloy using response surface methodology

  • Published:
Sādhanā Aims and scope Submit manuscript

Abstract

Inconel 625 is one of the most versatile nickel-based super alloy used in the aerospace, automobile, chemical processing, oil refining, marine, waste treatment, pulp and paper, and power industries. Wire electrical discharge machining (WEDM) is the process considered in the present text for machining of Inconel 625 as it can provide an effective solution for machining ultra-hard, high-strength and temperature-resistant materials and alloys, overcoming the constraints of the conventional processes. The present work is mainly focused on the analysis and optimization of the WEDM process parameters of Inconel 625. The four machining parameters, that is, pulse on time, pulse off time, spark gap voltage and wire feed have been varied to investigate their effects on three output responses, such as cutting speed, gap current, and surface roughness. Response surface methodology was used to develop the experimental models. The parametric analysis-based results revealed that pulse on time and pulse off time were significant, spark gap voltage is the least significant, and wire feed as a single factor is insignificant. Multi-objective optimization technique was employed using desirability approach to obtain the optimal parameters setting. Furthermore, surface topography in terms of machining parameters revealed that pulse on time and pulse off time significantly deteriorate the surface of the machined samples, which produce the deeper, wider overlapping craters and globules of debris.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
Figure 21
Figure 22
Figure 23
Figure 24
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29

Similar content being viewed by others

References

  1. Dinda G P, Dasgupta A K and Mazumder J 2009 Laser aided direct metal deposition of Inconel 625 superalloy: microstructural evolution and thermal stability. Mater. Sci. Eng. A. 509(1–2): 98–104

  2. Paul C P, Ganesh P, Mishra S K, Bhargava P, Negi J and Nath A K 2007 Investigating laser rapid manufacturing for Inconel-625 components. Opt. Las. Tech. 39(4): 800–805

    Article  Google Scholar 

  3. Singh V K and Singh S 2015 Multi-objective optimization using Taguchi based Grey relational analysis for wire EDM of Inconel 625. J. Mater. Sci. Mech. Eng. 2(11): 38–42

    Google Scholar 

  4. Chopde I K, Gogte C and Milind D 2014 Modeling and optimization of WEDM parameters for surface finish using design of experiments. In: Proceedings of the International Conference on Industrial Engineering and Operations Management, Bali, Indonesia

  5. Huang Yu, Ming Wuyi, Guo Jianwen, Zhang Zhen, Liu Guangdou, Li Mingzhen, and Zhang Guojun 2013 Optimization of cutting conditions of YG15 on rough and finish cutting in WEDM based on statistical analyses. Int. J. Adv. Manuf. Technol. 69(5): 993–1008

    Article  Google Scholar 

  6. Akbar A L and Saeed D 2013 The effect of operational cutting parameters on Nitinol-60 in wire electrodischarge machining. Adv. Mater. Sci. Eng. 457186: 6. doi:10.1155/2013/457186

    Google Scholar 

  7. Zhang G, Zhang Z, Ming W, Guo J, Huang Yu and Shao X 2013 The multi-objective optimization of medium-speed WEDM process parameters for machining SKD11 steel by the hybrid method of RSM and NSGA-II. Int. J. Adv. Manuf. Technol. 70(9): 2097–2109

    Google Scholar 

  8. Narendranath S, Manjaiah M, Basavarajappa S and Gaitonde V N 2013 Experimental investigations on performance characteristics in wire electro discharge machining of Ti50Ni42.4Cu7.6 shape memory alloy. Proc. I. Mech. Eng. Part B: J. Eng. Manuf. 227(8):1180–1187

  9. Gupta K and Jain N K 2014 Analysis and optimization of surface finish of wire electrical discharge machined miniature gears. Proc. I. Mech. Eng. Part B: J. Eng. Manuf. 228(5): 673–681

  10. Kumar Anish, Kumar Vinod and Kumar Jatinder 2013 Multi-response optimization of process parameters based on response surface methodology for pure Titanium using WEDM process. Int. J. Adv. Manuf. Technol. 68: 2645–2668

    Article  Google Scholar 

  11. Taweel T El and Hewid A 2012 Parametric study and optimization of WEDM parameters for CK45 steel. Int. J. Adv. Eng. Appl. 1(4): 47–61

    Google Scholar 

  12. Garg R 2010 Effect of process parameters on performance measures of wire electrical discharge machining. Ph.D. Thesis, Mechanical Engineering Department National Institute of Technology, Kurukshetra, India

  13. Sharma P, Chakradhar D and Narendranath S 2015 Multi-response optimization of WEDM process using hybrid approach while machining Inconel 625 superalloy. J. Mach. Form. Technol. 6(3–4): 1947–4369

    Google Scholar 

  14. Rodge M K, Sarpate S S and Sharma S B 2013 Investigation on process response and parameters in wire electrical discharge machining of Inconel 625. Int. J. Mech. Eng. Technol. 4(1): 54–65

    Google Scholar 

  15. Rajyalakshmi G and Venkata Ramaiah P 2013 Multiple process parameter optimization of wire electrical discharge machining on Inconel 825 using Taguchi grey relational analysis. Int. J. Adv. Manuf. Technol. 69: 1249–1262

    Article  Google Scholar 

  16. Ramakrishna R and Karunamoorthy L 2008 Modeling and multi response optimization of Inconel-718 on machining of CNC WEDM process. J. Mater. Process. Technol. 207: 343–349

    Article  Google Scholar 

  17. Newton T R, Melkote S N, Watkins T R, Trejo R M and Reister L 2009 Investigation of the effect of process parameters on the formation and characteristics of recast layer in wire-EDM of Inconel 718. Mater Sci. Eng. 513–514: 208–215

    Article  Google Scholar 

  18. Hewidy M S, El-Taweel T A and El-Safty M F 2005 Modelling the machining parameters of wire electrical discharge machining of Inconel-601 using RSM. J. Mater. Process. Technol. 169: 328–336

    Article  Google Scholar 

  19. Jain V K, Rao Sreenivasa P, Choudhary S K and Rajurkar K P 1991 Experimental investigations into traveling wire electrochemical spark machining (TW-ECSM) of composites. J. Manuf. Sci. Eng. 113(1): 75–84

    Article  Google Scholar 

  20. Montgomery D C 2002 Design and analysis of experiments, 4th edition, New York: Wiley

    Google Scholar 

  21. Gunaraj V and Murugan N 1999 Application of response surface methodologies for predicting weld base quality in submerged arc welding of pipes. J. Mater. Process. Technol. 88: 266–275

    Article  Google Scholar 

  22. Kwak J S 2005 Application of Taguchi and response surface methodologies for geometric error in surface grinding process. Int. J. Mach. Tool. Manuf. 45: 327–334

    Article  Google Scholar 

  23. Kim Chang-Ho and Kruth J P 2001 Influence of the electrical conductivity of dielectric on WEDM of sintered carbide. KSME. 15(12): 1676–1682

    Article  Google Scholar 

  24. Pandey P C and Shan H S 1980 Modern machining processes, 45th reprint 2012, New Delhi: Tata McGraw Hill

  25. Derringer G and Suich R 1980 Simultaneous optimization of several response variables. J. Q. Technol. 12: 214–219

    Google Scholar 

  26. Kumar Anish, Kumar Vinod and Kumar Jatinder 2014 Microstructure analysis and material transformation of pure titanium and tool wear surface after wire electric discharge machining. Mach. Sci. Technol. 18 (1): 47–77

    Article  Google Scholar 

Download references

Acknowledgements

The authors acknowledge M. M. University Mullana-Ambala, Haryana, India, for providing the necessary WEDM set-up for experimentation. The authors are also thankful to Mr. Pawan for providing help in the laboratory.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, D.A.V. University, Jallandhar, 144001, India

    M P GARG

  2. Department of Mechanical Engineering, Maharishi Markandeshwar University, Mullana-Ambala, 133207, India

    ANISH KUMAR & C K SAHU

Authors
  1. M P GARG
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. ANISH KUMAR
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. C K SAHU
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to ANISH KUMAR.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

GARG, M.P., KUMAR, A. & SAHU, C.K. Mathematical modeling and analysis of WEDM machining parameters of nickel-based super alloy using response surface methodology. Sādhanā 42, 981–1005 (2017). https://doi.org/10.1007/s12046-017-0647-3

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12046-017-0647-3

Keywords

Search

Navigation