Multi response optimization of process parameters using Response Surface Methodology in EDM of Inconel 825

Abstract

-Now days, mass production of complicated shapes of different components with high accuracy is very difficult and takes much time by conventional machining process. To get-rid of above said difficulties, Electrical Discharge Machine (EDM) is the one nonconventional machining process which is used very widely. In EDM, it is necessary to optimize the process parameters like pulse ontime, pulse off-time, discharge current, voltage, for maximization of Material Removal Rate (MRR) for INCONEL 825. Basically (EDM) is a well-established nonconventional machining process, used for manufacturing geometrically complex or hard and electrically conductive material parts that are extremely difficult-to-cut by other conventional machining processes. Erosion pulse discharge occurs in a small gap between the work piece and the electrode. This removes the unwanted material from the parent metal through melting and vaporizing in presence of dielectric fluid. Presence of metal particles in dielectric fluid diverts its properties, which reduces the insulating strength of the dielectric fluid and increases the spark gap between the tool and work piece. As a result, the process becomes more stable and surface finish increases. The EDM process is mainly used for making of dies, moulds, parts of aerospace, automotive industry and surgical components etc. For this purpose Response Surface methodology is adopted to determine the process parameter that optimizes the best machining process.