Title: Application of utility concept approach for multi-response optimisation of wire electrical discharge machining during profile cutting of Inconel-625

Authors: Sachin Ashok Sonawane; Mahesh Laxmikant Kulkarni

Addresses: Walchand Institute of Technology, Solapur-413006, Maharashtra, India ' Department of Mechanical Engineering, JSPM Narhe Technical Campus, Narhe, Pune-411041, Maharashtra, India

Abstract: This research study investigates the effects of machining factors such as on pulse-on time, pulse-off time, servo voltage, peak current, wire feed rate and wire tension on kerf widths at different locations on the profile, i.e., at straight cut, at an angle 90°, 70° and 30° along with surface roughness, overcut, MRR and surface topography of the machined surface while WEDM of Inconel-625. Taguchi's L27 orthogonal design was applied for the planning of experiments. The utility concept was used to translate the multi-response problem into a single equivalent response called overall utility index. Pulse on time was observed as the prime factor affecting the overall utility index. Surface topography of the machined samples shows craters, debris deposited on the machined surface and micro-cracks. This paper reports machining of the complex profile on Inconel-625 and optimisation of machining factors which will be helpful for the manufacturing industries to manufacture complex patterns.

Keywords: wire electrical discharge machining; WEDM; profile cutting; Taguchi method; utility concept; overall utility index; kerf width; MRR; surface finish; overcut; surface topography.

DOI: 10.1504/IJMMM.2018.089468

International Journal of Machining and Machinability of Materials, 2018 Vol.20 No.1, pp.13 - 47

Received: 11 Jul 2016
Accepted: 09 Feb 2017

Published online: 26 Jan 2018 *

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