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There is a need for heavy-duty machining equipment and tooling to minimize chatter due to work-hardening of the INCONEL materials ahead of cutting. Optimum EDM parameters are to be identified to produce quality products of INCONEL800. Modified Taguchi approach is adopted in the multi-objective optimization to identify the optimum peak current, pulse-on-time and pulse-off-time in the nano powder mixed EDM (n-PMEDM) of INCONEL800 with copper electrode for high material removal rate (MRR) and low surface roughness (SR). Empirical relations for MRR and SR are developed easily in terms of the EDM parameters without use of the MINITAB Release-16 software and validated with test results. Test results are found to be within the expected range. It also demonstrates the advantages of opting Taguchi approach to get complete information through few experiments.

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Metal matrix composites are extensively used in aerospace, automobile and other engineering applications as an alternative to a wide range of elements. High strength-weight ratio, durability and high corrosion resistance are benefits of metal matrix composites. The study that exhibits adopts optimal cutting parameters (speed, feed and depth of cut). The initial study is to explore end milling process of alumina (AA6082 with SiC 3% and fly ash 2%) molted metal matrix composite. The technique for order preference by similarity to ideal solution and fuzzy logic for optimizing the cutting parameter values has been utilized in the MMC. The response surface methodology is being used to develop the numerical model between output responses and machining parameters. The second-order regression models are studied through analysis of variance. The experimental investigation exhibits that feed rate is the important factor on response variables.