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Grey Relational Analysis-Based Multi-Response Optimization of Magnetic-Field-Assisted Powder-Mixed Electric Discharge Machining of Inconel 706

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Abstract

In the current study, an experimental investigation has been done using the hybrid magnetic-field-assisted powder-mixed electric discharge machining (MFAPMEDM) technique to enhance the process performance while machining Inconel 706 superalloy. Inconel 706 is a newly developed superalloy for aircraft applications. All the experimentation work was done according to Taguchi’s L9 orthogonal array (OA) to analyse the effect of controlled input parameters like peak current (Ip), pulse ‘ON’ (Pon) and pulse ‘OFF’ (Poff) duration on response parameters. Material removal rate (MRR), tool wear rate (TWR) and surface roughness (Ra) were selected as response parameters, and further multi-response optimization was done through grey relational analysis (GRA). GRA results revealed that Pon (62.84%) is the most influential input variable followed by Ip (28.64%) and Poff (8.50%) for controlling all the responses simultaneously. GRA optimized parameters were determined as Ip (5 A), Pon (50 µs) and Poff (20 µs). The surface morphology of the tool (cathode) and workpiece (anode) was assessed using field emission scanning electron microscopy (FESEM), which revealed the presence of partially melted crater boundaries/debris, micro-holes and debris on the surface. The results presented in this paper will help future researchers in studying the machining characteristics of the Inconel 706 superalloy.

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Abbreviations

Adj MS:

Adjusted mean square

Adj SS:

Adjusted sum of squares

ANOVA:

Analysis of variance

B4C:

Boron carbide

BBD:

Box–Behnken design

dB:

Decibels

Cu:

Copper

DF:

Degrees of freedom

DOE:

Design of experiments

EDM:

Electric discharge machining

EF:

Electric field

FESEM:

Field emission scanning electron microscope

FL :

Lorentz force

GA:

Genetic algorithm

Gr:

Graphite

GRA:

Grey relational analysis

GRC:

Grey relational coefficient

GRG:

Grey relational grade

Ip :

Peak current

MFAEDM:

Magnetic-field-assisted EDM

MFAPMEDM:

Magnetic-field-assisted PMEDM

MF:

Magnetic field

PC:

Powder concentration

MH:

Micro-hardness

MMCs:

Metal matrix composites

MRR:

Material removal rate

OA:

Orthogonal array

OC:

Overcut

OFAT:

One factor at a time

PMEDM:

Powder-mixed EDM

Pon :

Pulse ‘ON’ time

Poff :

Pulse ‘OFF’ time

Ra :

Surface roughness

RLT:

Recast layer thickness

RSM:

Response surface methodology

SCD:

Surface crack density

SiC:

Silicon carbide

S/N Ratio:

Signal/noise ratio

T:

Tesla

Ti:

Titanium

TLBO:

Teaching learning-based optimization

TWR:

Tool wear rate

W:

Tungsten

%:

Percentage of contribution

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Acknowledgements

This work was carried out at the Department of Production and Industrial Engineering, Punjab Engineering College (Deemed to be University), Chandigarh. The authors would also like to acknowledge SAIF, Panjab University, Chandigarh, for providing the FESEM facility.

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  1. Department of Production and Industrial Engineering, Punjab Engineering College, Deemed To Be University, Chandigarh, 160012, India

    Sushil Kumar, Mudimallana Goud & Narendra Mohan Suri

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  1. Sushil Kumar
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Kumar, S., Goud, M. & Suri, N.M. Grey Relational Analysis-Based Multi-Response Optimization of Magnetic-Field-Assisted Powder-Mixed Electric Discharge Machining of Inconel 706. Arab J Sci Eng 47, 8315–8339 (2022). https://doi.org/10.1007/s13369-021-06204-3

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