Investigation of Machining Characteristics of nickel-based alloy with Copper Coating and Application of Magnet by using DS-EDM Process

Nickel based super alloy material are extensively used in various industrial applications such as aerospace, automobile etc., due to their unique mechanical and chemical properties. However, machining of such hard materials is most difficult by using traditional machining process and also increases the manufacturing time and cost as well as to reduce machine tool durability. Nontraditional machining techniques are playing a major role to resolve the issues present in traditional machining. This paper presents study and investigation of machining characteristics of a non-contacting or non-traditional machining such as die-sinking electrical discharge machining (DS-EDM) process on nickel-based alloy Inconel 718 material with copper coating and application of magnet. Further, the investigation is performed based on Taguchi L-16 orthogonal array to analyze the DS-EDM process dependent parameters like material removal rate (MRR) and tool wear rate (TWR) and corresponding independent parameters are current, pulse-ON, duty cycle and voltage. Furthermore, statistical significance analysis tools via. parametric analysis, ANOVA and 3D response is carried out to evaluate the effect of input variables on output variables of DS-EDM. The result shows that the optimal parameter setting is obtained (i.e., current at 4 amps, pulse-on at 40 µs, duty cycle at 10 µs and voltage at 40 v) by using MOORA optimization technique and achieved quality products with higher production throughput.