What question did this study set out to answer?

This research aims to optimize machining conditions for Inconel 825 using Wire Electrical Discharge Machining (WEDM) to improve surface roughness and taper error.

March 23, 2026

Ann Modeling and Investigation on The Surface Roughness and Taper Error While Machining The Inconel 825 Alloy Material Using Wire-Cut Edm Process

Puntos clave

This research aims to optimize machining conditions for Inconel 825 using Wire Electrical Discharge Machining (WEDM) to improve surface roughness and taper error.
Utilized Wire Electrical Discharge Machining (WEDM) for Inconel 825 machining.
Applied Central Composite Design (CCD) to examine effects of machining parameters.
Developed predictive models using Response Surface Methodology (RSM) and Artificial Neural Network (ANN).
Conducted ANOVA to assess parameter significance.
Performed multi-objective optimization with desirability approach.
Pulse-on time significantly affects surface roughness, while pulse-off time influences taper error.
Achieved optimal settings: Pulse-on time = 0.6 μs, Pulse-off time = 40 μs, Wire tension = 12 N, Taper angle = 3°.
Surface roughness of 0.44 μm and taper error of 0.07° reached under optimized conditions.
Artificial Neural Network demonstrated high prediction accuracy (R2 up to 0.9999).
SEM analysis confirmed minimal surface defects with optimal parameters.

Resumen

Inconel 825 alloy is difficult to machine using conventional processes due to its superior mechanical and thermal properties. Wire Electrical Discharge Machining (WEDM) offers a viable alternative, yet optimizing taper cutting accuracy and surface quality remains underexplored, particularly for complex profiles. This study investigates the effects of pulse-on time, pulse-off time, wire tension, and taper angle on surface roughness (SR) and taper error (TE) during WEDM of Inconel 825 using Central Composite Design (CCD). Response Surface Methodology (RSM) and Artificial Neural Network (ANN) models were developed to predict responses, with ANN demonstrating superior accuracy (R 2 up to 0.9999). ANOVA revealed pulse-on time as the most significant parameter affecting SR, while pulse-off time most influenced TE. Multi-objective optimization using the desirability approach yielded optimal parameters: T on = 0.6 μs, T off = 40 μs, WT = 12 N, TA = 3°, achieving a desirability value of 1.00, with SR = 0.44 μm and TE = 0.07°. SEM analysis confirmed minimal surface defects under optimized conditions. The study provides reliable predictive models and optimal settings for high-precision taper cutting of Inconel 825, bridging a critical research gap in non-traditional machining of high-performance alloys.

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