IMPROVEMENT IN THE RECAST LAYER THICKNESS, CORNER RADIUS AND SURFACE ROUGHNESS OF MONEL K 400 THROUGH CFRP, NANO-SiC, AND ZrSiO₄ PARTICLES ADDED WIRE EDM

Abstract

Monel K 400 is a potential superalloy that is used in heat exchanger piping, process vessels, gasoline, and portable water owing to superior mechanical properties at zero temperature. Square holes are needed in the high-temperature application components and are difficult to machine using conventional methods. Hence, in this study, the square holes have been fabricated on Monel K 400 superalloys with varying pulse duration, current, pulse interval, and servo voltage and its influences on Recast Layer Thickness (RLT), Corner Radius (CR), and Surface Roughness (SR) have been analyzed. Experiments are planned on using Taguchi design and the responses are analyzed with mean surface plots. The overall analysis found that the SiC powder mixed in EDM oil has a larger improvement % than that of CFRP and ZrSiO4 powder. The performance of SiC powder mixed in EDM oils increased to 62 % for RLT, 32 % for CR, and 51 % for SR. The current and pulse duration are revealed to be the most significant parameters using Analysis of Variance (ANOVA). Quadratic and Adaptive Neuro-Fuzzy Inference System (ANFIS) models are developed for prediction. The Mean Absolute Percentage Error (MAPE), coefficient of determination (R), and Root Mean Square Error (RMSE) are calculated for evaluating the models and it is discovered that both models have low RMSE, MAPE, and high R. Finally, the multiple response decision making based on Taguchi based Data Envelopment Analysis based Ranking (DEAR) methodology is an improvement of 28 % for RLT, a 16 % for CR, and a 21 % for SR.