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Optimization and Microstructural Studies on the Machining of Inconel 600 in WEDM Using Untreated and Cryogenically
Satyanarayana Kosaraju1, Phaneendra Babu Bobba2, Surender Reddy Salkuti3
1Department of Mechanical Engineering, Gokaraju Rangaraju Institute of Engineering and Technology, Hyderabad 500090, India.
Materials (Basel, Switzerland)
|April 28, 2023
Summary
This study investigated wire electrical discharge machining (WEDM) parameters for Inconel 600. Pulse-off time significantly impacted material removal rate and surface roughness with zinc electrodes.
Area of Science:
- Manufacturing Engineering
- Materials Science
- Surface Engineering
Background:
- Wire Electrical Discharge Machining (WEDM) is crucial for manufacturing components from challenging alloys like Inconel.
- Optimizing WEDM parameters is essential for achieving desired material removal rates (MRR) and surface quality (Ra).
Purpose of the Study:
- To investigate the influence of WEDM process parameters on Inconel 600 alloy.
- To compare the effects of untreated and cryogenically treated zinc electrodes on machining performance.
- To identify key parameters affecting material removal rate (MRR) and surface roughness (Ra).
Main Methods:
- Experiments were conducted using controllable parameters: current (IP), pulse-on time (Ton), and pulse-off time (Toff).
- Taguchi analysis was employed to evaluate the influence of each parameter on MRR and Ra.
- Microstructural analysis using Scanning Electron Microscopy (SEM) and Energy-Dispersive X-ray Spectroscopy (EDS) examined surface characteristics and material composition.
Main Results:
- Pulse-off time was identified as the most influential parameter on both MRR and Ra for both electrode types.
- Interactions with pulse-off time significantly affected machining outcomes.
- SEM and EDS analyses provided detailed insights into surface integrity and elemental composition.
Conclusions:
- WEDM parameter optimization, particularly pulse-off time, is critical for efficient machining of Inconel 600.
- Cryogenic treatment of zinc electrodes may offer advantages in WEDM performance.
- Understanding microstructural changes is vital for predicting and controlling WEDM outcomes.
