Optimization of Process Parameters in Wire Electro Discharge Machining during Taper Cutting of Inconel 625

Abstract

An experimental study has been carried out during taper cutting of Inconel 625 super alloy in Wire electro discharge machining(WEDM).Taking three input process parameters viz. workpiece thickness, taper angle, peak current and pulse on time experiments have been carried out. Effect of the input process parameters on the various output performance parameters like material removal rate(MRR), Surface roughness(Ra),Angular error have been analyzed.Taguchi L9 orthogonal array has been employed for the design of experiments.An ANSYS thermal modelling have also been developed. Comparison was done between the theoretical MRR obtained from modelling and the experimental results.Taguchi grey relational analysis(GRA) has also been performed. In addition to this white layer thickness has been measured on the machined surface of workpiece. Additionally EDS analysis has also been carried out to investigate the change in chemical composition of the work surface before and after machining.