A Project on

Optimization of WEDM Parameters on Machining Inconel 750

Super alloy

PRESENTED BY
SOUVIK GANTAIT
Under the guidance of

Prof Venkateswara Rao G

DEPT-CIM
ROLL NO-133567
NATIONAL INSTITUTE OF TECHNOLOGY,WARANGAL

INTRODUCTION
Wire EDM is not the new kid on the block. It was

introduced in the late 1960s', and has revolutionized

the tool and die, mold, and metalworking industries. It
is probably the most exciting and diversified machine
tool developed for this industry in the last fifty years,
and has numerous advantages to offer.
WEDM process involves the complex erosion effect
by rapid repetitive and discrete spark discharges
between the wire tool electrode and work piece
immersed in a liquid dielectric medium.

Schematic Diagram of WEDM

LITERATURE REVIEW
Kuriakose and Shunmugam have prepared a multiple

regression model used to represent relationship between

input and output variables and a multi-objective
optimization method based on a Non-Dominated Sorting
Genetic Algorithm (NSGA) used to optimize Wire-EDM
process. [1]
Mahapatra and Patnaik have considered metal removal
rate (MRR), surface finish (SF) and cutting width (kerf)
as performances to solve multi response optimization
problem using Taguchi method first and secondly using
Genetic Algorithm. [2]

LITERATURE REVIEW
Tosun et al. determined the effect of machining parameters on

the cutting width and material removal rate based on the

Taguchi method. [3]
Esme et al. modeled the surface roughness in WEDM process
using design of experiments and neural networks. [4]
Kumar Muthu, Babu Suresh, et all demonstrates optimization
of Wire Electrical Discharge Machining process parameters
of Incoloy800 super alloy with different performance
characteristics such as Material Removal Rate (MRR),
surface roughness and Kerf based on the Grey relational and
Taguchi Method.[5]

WORK MATERIAL
Component

Wt. %

Ni

Min 70

Si

Max 0.5

Ti

2.25 - 2.75

Cu

Max 0.5

Fe

5-9

Mn

Max 1

Nb

0.7 - 1.2

Al

0.4 - 1

Max 0.08

Co

Max 1

Cr

14 - 17

APPLICATION AREAS OF THIS

MATERIAL
Nuclear reactors
Gas turbines
Rocket engines
Pressure vessels
Aircraft structure

MOTIVATION
The wire electro-discharge machining process (WEDM)

has become very popular in the tool-making industry, in

which complex geometries with tight tolerances must be
generated on difficult-to-machine materials.
For machining hard materials such as Ni based super
alloy it is hard to cut using conventional machining. Also
it is difficult to get good surface finish and better MRR.
Kerf is also one parameter which should be optimized.
Machining data for Incoloy 750 using WEDM is not
available

OBJECTIVE
Identification of significant process parameters while

machining Inconel 750 using various tool materials on the

response parameters such as Surface roughness, Kerf &
MRR.
Maximizing MRR.
Improving surface roughness.
Minimizing kerf.
Optimization of process parameters with the above
conditions.

WORK DONE TILL LAST REVIEW

Problem defined
Collected research paper regarding topic.
Identification of the process to follow.

WORK DONE DURING THE REVIEW PERIOD:

Collected more journal papers regarding my topic.
Studied Taguchi design.
Studied about GA.

Algorithm
-Randomly generate an initial population M(0)
Compute and save the fitness u(m) for each individual m in

the current population M(t)

Define selection probabilities p(m) for each individual m in
M(t) so that p(m) is proportional to u(m)
Generate M(t+1) by probabilistically selecting individuals
from M(t) to produce offspring via genetic operators
Repeat step 2 until satisfying solution is obtained.

DESIGN OF EXPERIMENT
Factors: Peak current (A), Pulse on time (B), Pulse off time(C),

Gap voltage (D)

Levels: 3 levels for each factor.
Levels of A: 6A, 12A, 18A
Levels of B: 100s, 105 s, 110 s.
Levels of C: 40 s, 41 s, 42 s.
Levels of D: 25V, 30V, 35V.
Output Parameters: Surface roughness (Y1), Material removal rate
(Y2), Kerf (Y3).
Taguchis 3^4 orthogonal array experimental design is then
selected.

Spark On-time (pulse time or Ton):The duration of time (s) the current is
allowed to flow per cycle

Spark Off-time (pause time or Toff ):The duration of time (s) between the
sparks (that is to say, on-time).

) Discharge current (current Ip): Current is measured in amp Allowed

to per cycle. Discharge current is directly proportional to the Material
removal rate

WORKS TO BE DONE
Work Material to be purchased.
Experiment to be done as per the set up made.
Analysis of variance (ANOVA).
Codes for optimization.
Validation of experiment.
Thesis writing.

REFFERENCES
Kuriakose, S.; Shunmugam, M. S. (2005). Multi-objective optimization of wire-electro

discharge machining process by Non-Dominated Sorting Genetic Algorithm, Journal

of
Materials
Processing
Technology,
Vol.170
,No.1-2,
133141,
doi:10.1016/j.jmatprotec.2005.04.105
Mahapatra, S. S.; Patnaik, A. (2006). Optimization of wire electrical discharge
machining (WEDM) process parameters using Taguchi method, International Journal
of
Advanced Manufacturing Technology, Vol. 34, No. 9-10, 911-925, doi:
10.1007/s00170-006-0672-6
N. Tosun, C. Cogun, G. Tosun, Journal of Materials ProcessingTechnology, 152(2004),
316322
U. Esme, A. Sagbas, F. Kahraman, Iranian Journal of Science &Technology, Transaction B,
Engineering, 33(2009), 231240
Muthu Kumar, Suresh Babu, et all, Optimization of the WEDM Parameters on
Machining Incoloy800 Super alloy with Multiple Quality Characteristics International
journal of Engineering and Science and technology, Vol. 2(6), 2010, 1538-1547