Modeling and optimization of Electro Discharge Machining (EDM) process parameters for machining of inconel 600 super alloy
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Date
2018-01
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G.B. Pant University of Agriculture and Technology, Pantnagar - 263145 (Uttarakhand)
Abstract
In last few years, Inconel 600 superalloy gained much attention of researchers due to its properties viz. high impact strength at room temperature, high hardness, high melting point, high electrically conductivity, corrosion resistance etc. Due to such excellent properties, Inconel 600 superalloy is an ideal choice for the numerous industrial applications, such as manufacturing the components related to aero-engine, spacecraft, nuclear, chemical, food processing, furnace, gas turbine, fixtures, heat exchanger, roller and hearths etc. However, the machining process in Inconel 600 superalloy with traditional machining processes is very difficult due to its poor machinability, high cost and more time consumption. In non-traditional machining processes, electrical discharge machining (EDM) has been regarded as the most efficient for the machining of Inconel 600 superalloy. Many investigations have already been done on the machining of Inconel 600 superalloy with EDM using different electrodes (copper, brass, graphite, molybdenum, copper tungsten). However, the effect of tungsten carbide as a tool electrode, on the machining of Inconel 600 superalloy has not been available in the literature. Therefore, machining of Inconel 600 superalloy with EDM using tungsten carbide as a tool electrode has been presented in this work to determine the effect of different process parameters on the various machining performance parameters. Experimental work has been planned in two phases. In the first phase, parametric optimization of EDM process for performance characteristics performed using Taguchi method. An orthogonal array (OA) L9 was used to conduct the experiments at three levels. Signal to Noise ratio (S/N) and analysis of variance (ANOVA) were employed to study the EDM performance characteristics. Optimization of parameters was done by Taguchi method using statistical software MINITAB-17. Confirmation tests were carried out with optimal levels of process parameters to validate the Taguchi's optimization method. The above results were validated by conducting confirmation experiments. In second phase, mathematical models have been developed for various performance characteristics of the EDM process by RSM using statistical software Design-Expert-9.0. The experiments performed using face centered central composite design and 30 runs were used to conduct the experiments. A standard second-order experimental design called face-centered central composite design (CCD) has been adopted for analyzing and modeling the EDM process parameters for performance characteristics. Predicted optimal ranges of MRR, TWR, WR, OC and SR at 95% confidence level were 30.67 mm3/min, 0.551mm3/min, 2.225, 0.012 mm and 6.684 μm respectively, which were validated by conducting confirmation experiments. Confirmation tests were also carried out with optimal levels of process parameters to validate the desirability function combination with RSM.
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