Influence of process parameters on MRR, kerf width and surface roughness during WEDM on Inconel 718: performance analysis of electrode tool material

In the present study, an attempt has been made to study the performance of (brass wire electrode and zinc coated brass wire electrode) wire electrodes in relation to material removal rate (MRR), kerf width and surface roughness of machined Inconel 718 obtained by wire electro discharge machining (WEDM) process. Experiments have been conducted using L16 orthogonal array with two different types of wire electrodes and by tuning following controllable process parameters; discharge current, flushing pressure, wire tension, and pulse-on time. It has been observed that zinc coated brass wire produces lesser kerf width as well as surface roughness; higher MRR as compared to brass wire electrode. The pulse-on time is found to be the most significant factor on influencing MRR for all electrodes types. Pulse-on time and discharge current is found to be very significant on affecting kerf width for all electrodes types finally, Grey-Taguchi relational analysis have been adopted to establish the optimal parametric combination for both the wire electrode.