Use of gamma coated wire to optimize the WEDM process parameters for Nitronic-30

Abstract

Due to the complicated and non-linear behaviour, efficient and economical application of Wire Electrical Discharge
Machining (WEDM) method is a challenge for the cutting-edge manufacturing period. The goal of the current study is to determine the best combination of input process parameters to achieve optimum material removal rate (MRR) and surface roughness (SR). Nitronic-30 is an austenitic stainless steel that has a high strength and good corrosion-resistant qualities. It has a wide range of possible uses in solid handling equipment, aqueous applications, and automotive components. Therefore, multiobjective optimization of Nitronic-30 on WEDM is necessary. RSM-based Box Behnken design of experiments have been conducted using machining factors such as pulse on time (Ton), pulse off time (Toff), peak current (IP), and servo voltage (SV). Gamma-coated wire have been used as the electrode material for the present analysis. This is the distinguishing factor of the current research. Surface roughness and material removal rate are two response variables that have been evaluated using Minitab-17 software. The process parameters proposed by Grey Relational Analysis (GRA) are Ton 115 (MU), Toff 50 (MU), IP 150 (A), and SV 60 (V) for obtaining optimal response variables as 2.07 μm for SR and 4.74 mm³/min for MRR, respectively.