WIRE ELECTRICAL DISCHARGE MACHINING ON NICKEL BASED ALLOYS

Abstract

today's aerospace, medical, nuclear, and automotive industries, newly created materials have taken up more space in order to manufacture components capable of withstanding harsh working conditions. Due to their enhanced mechanical and physical qualities, materials such as nickel, titanium, cobalt-based alloys, ceramics, and composites are considered to be advanced high strength materials. Titanium is a popular material in the aerospace and medical sectors because to its light weight and strong corrosion resistance. Additionally, titanium and its alloys exhibit fatigue strength, fracture toughness, enhanced operating temperature, and an increased strength-to-weight ratio. The conversion of these sophisticated high strength materials to the user-required component via conventional machining is found to be extremely difficult and economically unfeasible. WEDM process parameters are reported. The analysis as a whole is successful in finding operating characteristics that demand attention while machining aerospace materials such as Inconel-625, Nimonic-75, and Titanium Grade-5. SEM analysis was used to determine the surface topography of machined samples. Utility theory was used to perform multi-objective optimization. The kerf width of Titanium grade- 5 is observed to be greater with higher values of pulse on time. This is because when the pulse on time is increased, a great amount of thermal energy is created during the machining process, and because titanium is a poor conductor of heat, the thermal energy produced is focused at the cutting zone. This leads in a greater amount of material melting and vaporizing at the given spot.