Multi-objective optimization of wire-EDM of Inconel 625 by using desirability function approach

• Published in: International journal on interactive design and manufacturing 2023-04, Vol.17 (2), p.931-938
• Main Authors: Kar, Swastik Kumar, Mishra, Pradeep Kumar, Sahu, Anshuman Kumar, Mahapatra, Siba Sankar, Thomas, Joji
• Format: Article
• Language: English
• Subjects: CAE) and Design; Chromium steel; Computer-Aided Engineering (CAD; Content analysis; Corrosion resistance; Design of experiments; Distilled water; EDM electrodes; Electric discharge machining; Electrodes; Electronics and Microelectronics; Engineering; Engineering Design; Experimentation; Experiments; Heat treating; Industrial Design; Instrumentation; Kerf; Material removal rate (machining); Mechanical Engineering; Multiple objective analysis; Neural networks; Nickel base alloys; Optimization; Optimization techniques; Original Paper; Orthogonal arrays; Oxidation; Process parameters; Superalloys; Surface roughness; Titanium alloys; Variance analysis; Wire; Workpieces; Zinc coatings
• ISSN: 1955-2513; 1955-2505
• DOI: 10.1007/s12008-022-01184-6

Wire electro-discharge machining (Wire-EDM) is one of the most versatile and efficient manufacturing process to machine difficult-to-cut materials. In this experiment, wire-EDM of Inconel 625 work piece material is performed by using zinc coated brass wire as wire electrode and distilled water as dielectric fluid. Input parameters taken during experimentation are pulse-on-time (T on ), pulse-off-time (T off ), and servo voltage (S v ). Here, experiments are conducted as per Taguchi’s experimental design i.e. L 9 orthogonal array to study the effect of machining parameters on the output responses. To access the machining performance of the wire-EDM process during machining of Inconel 625, the output responses considered are material removal rate (MRR), kerf width (K w ), and average surface roughness (R a ) of the machined surface. For multi-objective optimization of these output responses during the wire-EDM process, desirability function approach is used to achieve better machining performance i.e. higher MRR, lower K w and lower R a . The optimum parametric setting for better machining performance is obtained to be T on  = 18 µm, T off  = 53 µm, S v  = 23 V. Also, analysis of variance (ANOVA) is performed to study the influence of machining parameters on the overall output performance (composite desirability). Here, pulse-on-time is found to be the highest significant factor with percentage contribution of 64.14% for composite desirability.