Abstract
In this study, the gray relational analysis method was used to optimize the micro-electrical discharge machining (EDM) drilling process of Inconel 718 nickel-based superalloy with multiperformance characteristics. In order to determine the best factor level conditions, a full factorial experimentation was performed based on the micro-EDM parameters of discharge current and pulse duration. The hole taper ratio (H t) and hole dilation (H d) were the measured performances. By analyzing the used optimization results, it was observed that the pulse current was more efficient on performance characteristics than pulse duration. The characteristics of drilled surfaces and tool electrodes were also investigated by using optical and scanning electron microscopy. A linear regression model was developed to estimate the performances. The measured and model results were in a good agreement with correlation coefficients of R 2 = 0.897 and R 2 = 0.929 for H t and H d, respectively. It is concluded that the EDMed hole quality can be improved effectively through this approach.
Similar content being viewed by others
References
Rao R, Yadava V (2009) Multi-objective optimization of Nd: YAG laser cutting of thin superalloy sheet using grey relational analysis with entropy measurement. Optic Laser Technol 41:922–930
Avanish Kumar D, Vinod Y (2008) Multi-objective optimization of Nd: YAG laser cutting of nickel-based superalloy sheet using orthogonal array with principal component analysis. Opt Lasers Eng 46:124–132
Hong-qin GUO, Jing-yu PEI, Wu-yi LI (2005) Process study of micro hole in EDM. Aerosp Manuf Technol 5:16–18
Young Hun J, Byung-Kwon M (2007) Geometry prediction of EDM-drilled holes and tool electrode shapes of micro-EDM process using simulation. Int J Mach Tool Manuf 47:1817–1826
Yeo SH, Tan LK (1999) Effects of ultrasonic vibrations in micro-electrodischarge machining of microholes. J Micromech Microeng 9:345–352
Öpöz TT, Ekmekçi B, Erden A (2009) An experimental study on the geometry of microholes in microelectric discharge machining. Mater Manuf Process 24:1236–1241
Yeo SH, Tan PC, Aligiri E, Tor SB, Loh NH (2009) Processing of Zirconium-based bulk metallic glass (BMG) using micro electrical discharge machining (Micro-EDM). Mater Manuf Process 24:1242–1248
Pellicer N, Crurana J, Özel T (2009) Influence of process parameters and electrode geometry of feature micro-accuracy in electro discharge machining of tool steel. Mater Manuf Process 24:1282–1289
Yeo SH, Aligiri E, Tan PC, Zarepour H (2009) A new pulse discriminating system for microEDM. Mater Manuf Process 24:1297–1305
Somashekhar KP, Ramachandran N, Mathew J (2010) Optimization of material removal rate in micro-EDM using artificial neural network and genetic algorithms. Mater Manuf Process 25:467–475
Tosun N (2006) Determination of optimum parameters for multiperformance characteristics in drilling by using grey relational analysis. Int J Adv Manuf Technol 28:450–455
Lin ZC, Ho CY (2003) Analysis and application of grey relation and ANOVA in chemical–mechanical polishing process parameters. Int J Adv Manuf Technol 21:10–14
Chang CL, Tsai CH, Chen L (2003) Applying grey relational analysis to the decathlon evaluation model. Int J Comput Internet Manage 11(3):54–62
Chang CK, Lu HS (2007) Design optimization of cutting parameters for side milling operations with multiple performance characteristics. Int J Adv Manuf Technol 32:18–26
Deng JL (1992) The essential methods of grey systems. Huazhong University of Science and Technology Press, Wuhan
Fung CP (2003) Manufacturing process optimization for wear property of fiber-reinforced polbutylene terephthalate composites with grey relation analysis. Wear 254:298–306
Yang YK (2006) Optimization of injection–molding process for mechanical and tribological properties of short glass fiber and polytetrafluoroethylene reinforced polycarbonate composites with grey relational analysis: a case study. Polym-Plast Technol Eng 45:769–777
Yang YY, Shie JR, Huang CH (2006) Optimization of dry machining parameters for high purity graphite in end-milling process. Mater Manuf Process 21:832–837
Çaydaş U, Hasçalık A (2008) Use of grey relational analysis to determine optimum laser cutting parameters with multi-performance characteristics. Optic Laser Technol 40:987–994
Yuanganga W, Fulinga Z, Jin W (2009) Wear-resist electrodes for micro-EDM. Chin J Aeronaut 22:339–342
Kumar S, Singh R, Singh TP, Sethi BL (2008) Surface modification by electrical discharge machining: a review. J Mater Process Technol
Newtona TR, Melkotea SN, Watkinsb TR, Trejob RM, 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 208–215
Lee H-T, Rehbach WP, Hsu F-C, Tai T-Y, Hsu E (2004) The study of EDM hole-drilling method for measuring residual stress in SKD11 tool steel. J Mater Process Technol 149:88–93
Hung Sung L, Biing Hwa Y, Chien Liang C, Fuang Yuan H (2006) Application of micro-EDM combined with high-frequency dither grinding to micro-hole machining. Int J Mach Tool Manuf 46:80–87
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Ay, M., Çaydaş, U. & Hasçalık, A. Optimization of micro-EDM drilling of inconel 718 superalloy. Int J Adv Manuf Technol 66, 1015–1023 (2013). https://doi.org/10.1007/s00170-012-4385-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-012-4385-8