Experimental Optimization of Process Parameters with Wire-EDM on Inconel 625

: Inconel 625 Alloy was developed as a nickel-chromium alloy solid solution strengthened by its content of molybdenum and niobium. The alloy had two main areas of application like resistance to aqueous corrosion at ambient to slightly elevated temperatures and for high strength and resistance to creep, rupture, and corrosion at high temperatures, therefore had been widely used for more than five decades in the marine and petroleum industries for applications requiring high strength, fracture toughness, fabric-ability and resistance to corrosion. Inconel 625 is one such super alloy which has very good mechanical and thermal properties, and it is difficult to machine with traditional machining processes due to the high melting point and hardness. So, Wire EDM is a non - conventional machining process which is mainly used to machine hard and tough materials like Inconel 625. Design of experiment for three-level on six parameters i.e. peak current, pulse on time, pulse off time, wire feed rate, servo voltage and flushing pressure has obtained using MINITAB 18. Taguchi L27 orthogonal array along with ANOVA is used for optimizing the different parameters such to get maximum material removal rate and maximum hardness is obtained and confirmation test has been done for HV as Taguchi combination is not according to the design of experiments. like peak current, pulse on time, pulse off time, wire feed rate, servo voltage and flushing pressure. Taguchi L27 orthogonal array along with ANOVA is used to optimize the different parameters such to get maximum material removal rate and maximum hardness is obtained. The wire of diameter 0.25 mm is tensioned between the lower and upper guide to obtained higher accuracy and Wire made of brass is used for the experiment. Dielectric fluid is deionized water with 12 to 16 TDS (total dissolved solids). Design of experiment for Taguchi orthogonal array, S/N and Mean table along their graphs to find the optimized combination of process parameters and ANOVA table for the contribution of parameters for MRR and HV has obtained using MINITAB 18.