Optimization and Microstructural Studies on the Machining of Inconel 600 in WEDM Using Untreated and Cryogenically Treated Zinc Electrodes
Any industry that manufactures dies, punches, molds, and machine components from difficult-to-cut materials, such as Inconel, titanium, and other super alloys, largely relies on wire electrical discharge machining (WEDM). In the current study, the effect of the WEDM process parameters on Inconel 600...
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| Language: | English |
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MDPI AG
2023-04-01
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| Online Access: | https://www.mdpi.com/1996-1944/16/8/3181 |
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| author | Satyanarayana Kosaraju Phaneendra Babu Bobba Surender Reddy Salkuti |
| author_facet | Satyanarayana Kosaraju Phaneendra Babu Bobba Surender Reddy Salkuti |
| author_sort | Satyanarayana Kosaraju |
| collection | DOAJ |
| description | Any industry that manufactures dies, punches, molds, and machine components from difficult-to-cut materials, such as Inconel, titanium, and other super alloys, largely relies on wire electrical discharge machining (WEDM). In the current study, the effect of the WEDM process parameters on Inconel 600 alloy with untreated zinc and cryogenically treated zinc electrodes was investigated. The controllable parameters included the current (IP), pulse-on time (Ton), and pulse-off time (Toff), whereas the wire diameter, workpiece diameter, dielectric fluid flow rate, wire feed rate, and cable tension were held constant throughout the experiments. The significance of these parameters on the material removal rate (MRR) and surface roughness (Ra) was established using the analysis of the variance. The experimental data acquired using the Taguchi analysis were used to analyze the level of influence of each process parameter on a particular performance characteristic. Their interactions with the pulse-off time were identified as the most influential process parameter on the MRR and Ra in both cases. Furthermore, a microstructural analysis was also performed via scanning electron microscopy (SEM) to examine the recast layer thickness, micropores, cracks, depth of metal, pitching of metal, and electrode droplets over the workpiece surface. In addition, energy-dispersive X-ray spectroscopy (EDS) was also carried out for the quantitative and semi-quantitative analyses of the work surface and electrodes after machining. |
| first_indexed | 2024-03-11T04:48:08Z |
| format | Article |
| id | doaj.art-f45719747aa84c2491e501f40d8971bc |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-11T04:48:08Z |
| publishDate | 2023-04-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-f45719747aa84c2491e501f40d8971bc2023-11-17T20:14:16ZengMDPI AGMaterials1996-19442023-04-01168318110.3390/ma16083181Optimization and Microstructural Studies on the Machining of Inconel 600 in WEDM Using Untreated and Cryogenically Treated Zinc ElectrodesSatyanarayana Kosaraju0Phaneendra Babu Bobba1Surender Reddy Salkuti2Department of Mechanical Engineering, Gokaraju Rangaraju Institute of Engineering and Technology, Hyderabad 500090, IndiaDepartment of Electrical and Electronics Engineering, Gokaraju Rangaraju Institute of Engineering and Technology, Hyderabad 500090, IndiaDepartment of Railroad and Electrical Engineering, Woosong University, Daejeon 34606, Republic of KoreaAny industry that manufactures dies, punches, molds, and machine components from difficult-to-cut materials, such as Inconel, titanium, and other super alloys, largely relies on wire electrical discharge machining (WEDM). In the current study, the effect of the WEDM process parameters on Inconel 600 alloy with untreated zinc and cryogenically treated zinc electrodes was investigated. The controllable parameters included the current (IP), pulse-on time (Ton), and pulse-off time (Toff), whereas the wire diameter, workpiece diameter, dielectric fluid flow rate, wire feed rate, and cable tension were held constant throughout the experiments. The significance of these parameters on the material removal rate (MRR) and surface roughness (Ra) was established using the analysis of the variance. The experimental data acquired using the Taguchi analysis were used to analyze the level of influence of each process parameter on a particular performance characteristic. Their interactions with the pulse-off time were identified as the most influential process parameter on the MRR and Ra in both cases. Furthermore, a microstructural analysis was also performed via scanning electron microscopy (SEM) to examine the recast layer thickness, micropores, cracks, depth of metal, pitching of metal, and electrode droplets over the workpiece surface. In addition, energy-dispersive X-ray spectroscopy (EDS) was also carried out for the quantitative and semi-quantitative analyses of the work surface and electrodes after machining.https://www.mdpi.com/1996-1944/16/8/3181WEDMInconelmicrostructural studyoptimizationSEMregression model |
| spellingShingle | Satyanarayana Kosaraju Phaneendra Babu Bobba Surender Reddy Salkuti Optimization and Microstructural Studies on the Machining of Inconel 600 in WEDM Using Untreated and Cryogenically Treated Zinc Electrodes Materials WEDM Inconel microstructural study optimization SEM regression model |
| title | Optimization and Microstructural Studies on the Machining of Inconel 600 in WEDM Using Untreated and Cryogenically Treated Zinc Electrodes |
| title_full | Optimization and Microstructural Studies on the Machining of Inconel 600 in WEDM Using Untreated and Cryogenically Treated Zinc Electrodes |
| title_fullStr | Optimization and Microstructural Studies on the Machining of Inconel 600 in WEDM Using Untreated and Cryogenically Treated Zinc Electrodes |
| title_full_unstemmed | Optimization and Microstructural Studies on the Machining of Inconel 600 in WEDM Using Untreated and Cryogenically Treated Zinc Electrodes |
| title_short | Optimization and Microstructural Studies on the Machining of Inconel 600 in WEDM Using Untreated and Cryogenically Treated Zinc Electrodes |
| title_sort | optimization and microstructural studies on the machining of inconel 600 in wedm using untreated and cryogenically treated zinc electrodes |
| topic | WEDM Inconel microstructural study optimization SEM regression model |
| url | https://www.mdpi.com/1996-1944/16/8/3181 |
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