Study on Wire Electrical Discharge Machining of Inconel-625

Abstract

Wire Electrical Discharge Machining (WEDM) is one of the non-conventional methods for machining of materials that are difficult to machine using conventional means. In WEDM, the optimum machining process parameters are governed mainly by the properties of workpiece material. Determination of these parameters presents a challenge to machining process planners. Improperly selected parameters for WEDM may result in low Material Removal Rate (MRR), short-circuiting of wire, wire breakage and poor surface finish. In this paper, the effect of Pulse-on time, Gap voltage and Wire Feed Rate on Surface Roughness (SR) and Material Removal Rate in WEDM of Inconel-625 is analyzed. Experiments are carried out for a wide range of input parameters and analysis is carried out on their effects on machining performance. The results show that both MRR and SR increase with the increase in Pulse-on time. Also, the best surface finish (Ra = 3.5 μm) is obtained when the Pulseon time is below 15 μ sec. The maximum MRR is obtained at a Pulse-on time ranging between 20-25 μsec.