Document Type : Research Paper

Authors

• Pawan Kumar ¹
• Meenu Gupta ²
• Vineet Kunar ³

¹ Department of Mechanical Engineering, Chandigarh Engineering College, Landran ,Mohali, India

² Department of Mechanical Engineering, National Institute of Technology, Kurukshetra, India

³ Department of Mechanical Engineering, UIET, Maharishi Dayanand University, Rohtak, India

Abstract

The present research attempts to analyze the surface topography of WEDMed Inconel 825 concerning surface crack density (SCD_i) and recast layer thickness (RCL_t). Formation of cracks, recast layer, and heat-affected zone are the major issues in determining the final performance of the WEDM machined sample. In this study, WEDM characteristics viz. pulse on time (T_on), pulse off time (T_off), gap voltage (SV), peak current (IP), wire tension (WT), and wire feed (WF) are optimized for the response SCD_i and RCL_t by response surface methodology. The outcome manifests that the topography of the machined surface becomes more rougher at the increased value of T_on, IP, and SV. RSM emerges as a great tool in the development of a predicted model based on the desirability approach and finding optimal parametric combinationm which results in reduced SCD_i and RCL_t. At the optimum combination of process parameters, i.e., 109 machine unit T_on, 36 machine unit T_off, 54 V SV, 120A IP, 9 machine unit WT and 7 m/min WF, the values obtained for SCD_i and RCL_t are 0.00160 μm/μm² and 20.991μm, respectively with an error of less than 5%.  

Graphical Abstract

Keywords

• Wire-cut electrical discharge machining
• Inconel 825
• Surface crack density
• Recast layer thickness
• RSM
• Desirability

20.1001.1.22287922.2021.11.1.16.8

Main Subjects

• Machining