Experimental Investigation of process parameters influence on machining Inconel 800 in the Electrical Spark Eroding Machine

Abstract. The Electrical Spark Eroding Machining is an entrenched sophisticated
machining process for producing complex geometry with close tolerances in hard
materials like super alloy which are extremely difficult-to-machine by using
conventional machining processes. It is sometimes offered as a better alternative or
sometimes as an only alternative for generating accurate 3D complex shapes of macro,
micro and nano-features in such difficult–to-machine materials among other advanced
machining processes. The accomplishment of such challenging task by use of
Electrical Spark Eroding Machining or Electrical Discharge Machining (EDM) is
depending upon selection of apt process parameters. This paper is about analyzing the
influencing of parameter in electrical eroding machining for Inconel 800 with
electrolytic copper as a tool. The experimental runs were performed with various input
conditions to process Inconel 800 nickel based super alloy for analyzing the response
of material removal rate, surface roughness and tool wear rate. These are the measures
of performance of individual experimental value of parameters such as pulse on time,
Pulse off time, peak current. Taguchi full factorial Design by using Minitab release 14
software was employed to meet the manufacture requirements of preparing process
parameter selection card for Inconel 800 jobs. The individual parameter’s contribution
towards surface roughness was observed from 13.68% to 64.66%.