Effects of Die-Sinking Electro-Discharge Machining Parameters on Surface Roughness in Inconel 825 Alloy

Objective: The objective of this paper is to find the optimal machining parameters of Die-Sinking Electro-Discharge Machining on Inconel 825 alloy with nickel coated copper electrode for improving the process response. Methods: The effects of different parameters were studied on the machining responses. The machining parameters considered for this work were applied current, pulse on time and pulse off time and their effect on surface roughness response was studied. Findings: Taguchi optimization technique was employed to find the effect of machining parameters on Electro-Discharge Machining process responses. Besides, analysis of variance statistical method has been employed to predict the importance of individual machining parameters in the responses. The result of this research reveals that the proper selection of the input variables plays an important role in die-sinking EDM process. Applications: Ni base alloys are widely used in aviation, ship building and defense industries because of their better properties such as good impact strength, high ultimate tensile strength, high yield strength, high resistance to corrosion, retaining the strength even at high temperatures and fatigue resistance.