Optimization and Microstructural Studies on the Machining of Inconel 600 in WEDM Using Untreated and Cryogenically Treated Zinc Electrodes

Abstract

Any industry that manufactures dies, punches, molds, and machine components from difficult-to-cut materials, such as Inconel, titanium, and other super alloys, largely relies on wire electrical discharge machining (WEDM). In the current study, the effect of the WEDM process parameters on Inconel 600 alloy with untreated zinc and cryogenically treated zinc electrodes was investigated. The controllable parameters included the current (IP), pulse-on time (Ton), and pulse-off time (Toff), whereas the wire diameter, workpiece diameter, dielectric fluid flow rate, wire feed rate, and cable tension were held constant throughout the experiments. The significance of these parameters on the material removal rate (MRR) and surface roughness (Ra) was established using the analysis of the variance. The experimental data acquired using the Taguchi analysis were used to analyze the level of influence of each process parameter on a particular performance characteristic. Their interactions with the pulse-off time were identified as the most influential process parameter on the MRR and Ra in both cases. Furthermore, a microstructural analysis was also performed via scanning electron microscopy (SEM) to examine the recast layer thickness, micropores, cracks, depth of metal, pitching of metal, and electrode droplets over the workpiece surface. In addition, energy-dispersive X-ray spectroscopy (EDS) was also carried out for the quantitative and semi-quantitative analyses of the work surface and electrodes after machining.

Simulation and Optimization of Surface Roughness and Process Performance during Machining of HSS by Micro-WEDM Technology

“…This analysis was applied to the results of all the recorded data, both for the recorded values of the parameters of the roughness of the machined surface Ra, as well as for the recorded values of the performance parameter of the electrical discharge process MRR. In the case of the recorded data where the presence of outliers or extreme values was confirmed, based on the analysis, and it was not possible to establish a normal distribution, even in cases where the normality of the distribution of the data was not proven even after the exclusion of the confirmed outliers, exponential and Box–Cox transformations were performed, which ensured the correctness of the statistical analysis of experimentally measured values of monitored output-dependent parameters Ra and MRR in micro-WEDM of HSS [ 70 , 71 , 72 , 73 , 74 ].…”

Optimization of Wire EDM Process Parameters for Machining Hybrid Composites Using Grey Relational Analysis

“…The ANOVA approach was employed to determine the contribution made by all of the input parameters and errors in the discrepancy of answers. The user can then focus on the significant element that is most probable to lead to an alteration in the responses by assessing the role of the parameters in the changed responses and the impact of single parameters on the response variation [27].…”

Prediction and Multiparametric Optimization of the Machined Surface Quality of Tool Steels in Precise Wire Electrical Discharge Machining

“…On the basis of an analysis of the current state of the given issue, it can be concluded that several relevant experimental studies have been carried out to date, the aim of which was to contribute to the improvement of the quality of machined surfaces after EDM with a wire electrode in terms of dimensional and geometric accuracy and precise surface quality in terms of roughness parameters from the point of view of low thermal impact on surface and subsurface layers [11][12][13]. These experiments were performed from different points of view.…”