Optimization of Wire Electrical Discharge Machining of Inconel-625

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Abstract Inconel-625 is a nickel-alloy based material with superior properties such as high fatigue strength, high hardness, and oxidation resistance. These properties make it suitable for applications in marine, aerospace, and power generation industries. Due to its high hardness, the material is difficult to machine by conventional machining methods such as turning, milling or grinding. For this reason, an alternative method known as Wire Electrical Discharge Machining (WEDM) can be adopted for such materials. In this paper, WEDM is optimized through Taguchi optimization technique. Inconel-625 plates of 10 mm thickness were used as specimen in experimental work. It was found out that, the minimum surface roughness (SR) can be achieved for pulse-on time ( t on ), wire feed rate ( f w ) and gap voltage ( v g ) of 0.4 µ s, 8 mm/min and 68 V, respectively. It was also observed that for maximum material removal rate (MRR), the pulse-on time, wire feed rate and gap voltage should be 0.6 µ s, 10 mm/min, and 56 V, respectively. Finally, for improved material removal rate and surface roughness, it was observed that the pulse-on time, wire feed rate, and gap voltage should be 0.5 µ s, 8 mm/min, and 62 V, respectively.

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