Optimization of Electrical Discharge Machining Parameters for Deep Hole Drilling in Waspaloy

This project addresses the challenges of drilling deep holes in Waspaloy, an age-hardening austenitic nickel-based alloy commonly used in high-temperature applications. Waspaloy is very hard to machine. It has low thermal conductivity and high strength. The material is also abrasive and tends to work harden. When cut, the surface gets distorted and becomes harder than before. This leads to notching and chipping in later machining steps. As a result, the fit becomes even tighter. Additionally, the toughness of this alloy makes the chips hard to break, and the low thermal conductivity leads to heat buildup, further complicating the machining process. To overcome these challenges, we employed “Electric Discharge Machining (EDM)”, a contact-free material removal process. A copper tube with a 3mm diameter was chosen as the tool electrode for the EDM process. This approach effectively mitigates the issues associated with traditional machining methods, providing a viable solution for machining Waspaloy.