Professor of Mechanical Engineering and Smart Structures, School of Computing Engineering and Mathematics, Western Sydney University, Australia. His research interests cover Industry 4.0, Additive Manufacturing, Advanced Engineering Materials and Structures (Metals and Composites), Multi-scale Modelling of Materials and Structures, Metal Forming and Metal Surface Treatment.
Abstract—EDM is a renowned non-conventional machining process capable of producing precise tolerance on difficult to cut materials. However, machinability aspects of prodigious materials like Nimonic C-263 are yet to be explored. Thus, in the current study, various die sinking EDM process parameters are analyzed with reference to responses like material removal rate, tool wear rate, surface roughness and radial over cut on Nimonic C-263 super alloy. The machining parameters considered are Current (C), Pulse on-time (Ton), Pulse off-time (Toff) and Flushing Pressure (FP). The response variables observed are Material Removal rate (MRR), Tool Wear Rate (TWR), Surface Roughness (SR) and Radial Overcut (ROC). TAGUCHI L25 orthogonal array is considered for experimental design and fine grained graphite as tool electrode during experimentation. Multiple regression analysis is performed on each response to develop mathematical model which are later used to predict the responses using optimal parameters. The results revealed, current as an influential process parameter affecting all the responses. The models are verified by validation experiments.
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