SURFACE MORPHOLOGY AND MACHINABILITY ASPECTS IN WIRE-EDM OF INCOLOY-800 SUPERALLOY: AN EXPERIMENTAL EVALUATION AND MICROSTRUCTURE ANALYSIS

Ravi Pratap Singh, Ravinder Kataria, Mustufa Haider Abidi, Sudhir Ranjan, Ashutosh Kumar Gupta and Abdulrahman Al-Ahmari
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Ravi Pratap Singh: Department of Industrial and Production Engineering, Dr. B. R. Ambedkar National Institute of Technology, Jalandhar, Punjab 144011, India
Sudhir Ranjan: �Department of Mechanical & Industrial Engineering, IIT Roorkee, Uttarakhand 247667, India
Ashutosh Kumar Gupta: Department of Industrial and Production Engineering, Dr. B. R. Ambedkar National Institute of Technology, Jalandhar, Punjab 144011, India
Abdulrahman Al-Ahmari: �Industrial Engineering Department, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia

Surface Review and Letters (SRL), 2022, vol. 29, issue 08, 1-28

Abstract: This study investigated various performance measures — material removal rate (MRR), surface roughness (SR), and dimensional deviation (DD) — in wire cut electrical discharge machining of the Incoloy-800 superalloy under the effect of purposefully varied process inputs. Superalloys comprise a bright category of alloys that possess excellent mechanical strength at elevated temperatures, superior surface stability, magnificent creep resistance, and corrosion and oxidation resistance. Analysis of variance was performed to reveal influential and crucial inputs for machining measures; results were interpreted and modeled statistically. After conducting the experimental runs, the novel attempt has further been made to conduct the multi-response optimization with the desirability method and the teaching-learning-based optimization (TLBO) algorithm to develop the best process setting for optimizing all considered measures jointly. Furthermore, machined sample’s microstructure analysis was conducted with the scanning electron microscopy (SEM) analysis. The optimized parametric setting was obtained as follows: pulse on time: 2 μs, pulse off time: 4 μs, peak current: 2 A, and wire feed rate: 5 m/min. Obtained experimental values for MRR, SR, and DD were 0.936 mm/min, 3.797 μm, and 0.084 mm, respectively, with the combined desirability value of 0.601. Optimization values of MRR, SR, and DD through the TLBO method varied from predicted values by 3.01%, 6.86%, and 6.32%, respectively.

Keywords: Optimization; surface morphology; superalloy; teaching-learning-based optimization; wire cut electrical discharge machining (search for similar items in EconPapers)
Date: 2022
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DOI: 10.1142/S0218625X22501050

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