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This is a Experimental Study study (also classified as: Quantitative Study).

September 16, 2025Open Access

Examination of The Process Parameters for Machining Nimonic Alloy 75 on WEDM with A Cryogenically Treated Tool

Key Points

The cryogenically treated tool achieved a surface roughness of 4.78 µm and kerf width of 0.276 mm, outperforming the non-cryogenically treated tool.
Results were based on ANOVA applied to the data from experiments using Taguchi L9 Orthogonal Array to analyze machining parameters of Nimonic Alloy 75.
Key process variables included tool electrode type, wire feed rate, wire tension, Ton, and Toff, all significantly affecting machining outcomes.
Microstructures of workpieces were examined using a Scanning Electron Microscope, providing insights into the machining process's effectiveness.

Abstract

This investigative analysis examines how various process variables affect Surface Roughness (Ra) and Kerf Width (KW) during the WEDM process. The experiments used Nimonic Alloy 75 sheets as the raw material and tested two types of tool electrodes: cryogenically treated (CT) brass wires and non-cryogenically treated (NCT) brass wires. The main control variables evaluated in this study included the type of tool electrode, wire feed rate (WF), wire tension (WT), Ton, and Toff. The thickness of the Nimonic Alloy 75 and the diameter of the wire (0.25 mm) were kept constant throughout the operation. The design of experimentation was taken based on the Taguchi L9 Orthogonal Array (OA), and ANOVA was utilized to evaluate Ra, KW, and the microstructures of the workpieces, which were examined under a Scanning Electron Microscope for both types of electrodes. The results indicated that the optimized values for Ra and KW of the machined parts were 4.78 µm and 0.276 mm, respectively, when using the cryogenically treated tool, as it yielded better results compared to the non-cryogenically treated tool.

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