Optimisation of Process Parameters in Wire Electrical Discharge Machining of Inconel 718 Superalloy Using Taguchi-Grey Relational Analysis and Response Surface Methodology
Randomized trial optimizes WEDM parameters for Inconel 718, suggesting more efficient machining techniques.
Key Points
This research aims to optimize the WEDM process parameters for machining Inconel 718 superalloy using advanced analytical methods.
Utilized L27 Taguchi orthogonal array for experimental design with zinc-coated brass wire and deionised water.
Conducted multi-response optimization applying Grey Relational Analysis on parameters including pulse-on time, pulse-off time, servo voltage, and wire feed rate.
Validated results through regression analysis with R² = 0.94.
Identified optimal settings: Ton = 120 µs, Toff = 55 µs, SV = 30 V, WF = 6 m/min leading to MRR of 42.6 mm³/min, Ra of 1.84 µm, KW of 0.312 mm.
ANOVA indicated Ton is the most significant parameter contributing 39.2% to MRR and 51.4% to Ra.
SEM-EDS analysis revealed a recast layer thickness of 8–14 µm and an inverse correlation with servo voltage.