S.R.K.R.

ENGINEERING COLLEGE (A)

(Affiliated to JNTUK, Kakinada)
(Recognized by All India Council for Technical Education, New Delhi)
Accredited by NBA (UG), Civil, CSE, ECE, EEE, IT & Mech. Engg.
Recognized as Scientific and Industrial Research Organization
CHINA AMIRAM (P.O) :: BHIMAVARAM-534 204

DEPARTMENT OF MECHANICAL ENGINEERING

Certificate
This is to certify that the project work entitled “DIE SINKING EDM
OF NIMONIC-901 SUPER ALLOY” is the bonafide work submitted by Allu
Venkata Nagababu (Reg. No. 19B95A0302), Kanuri Sumanth (Reg. No
19B95A0316), Vuda Sai Kiran (Reg. No 18B91A03S7), Karri Rakesh(Reg. No
19B95A0317), Vipparthi Bhanu Teja (Reg. No. 18B91A03S5) and Kakumanu
Sai Teja (Reg. No 17B91A03B2) in the partial fulfillment of the requirement
for the award of the degree of BACHELOR OF TECHNOLOGY in
MECHANICAL ENGINEERING during the year 2021-2022.

Guide: HOD:
B. SoundaryaSanthoshi , M. Tech. Dr. K. Brahma Raju M.E., Ph. D.
Assistant Professor Professor & Head of the Department

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 CERTIFICATE OF EXAMINATION

This is to certify that we had examined the thesis and here by accord our
approval of it as a study carried out and presented in a manner required for its
acceptance in a partial fulfillment for the award of degree of BACHELOR OF
TECHNOLOGY in MECHANICAL ENGINEERING for which it has been
submitted.

This approval does not endorse or accept every statement made, opinion
expressed or conclusion drawn as in report. It only signifies acceptance of report
for the purpose for which it is submitted.

Internal Examiner External Examiner

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 ACKNOWLEDGEMENT

The satisfaction that accompanies the successful completion of any task would

be incomplete without the mention of the people who made it possible and whose

constant guidance and encouragement crown all the efforts success.

I thank my guide Dr. B. Soundarya Santhoshi, Professor in Department of

Mechanical Engineering for his support in completion of my Dissertation. I wish to

express my sincere thanks to Prof. K. Brahma Raju, Head of the Department and all

faculty members of Department of Mechanical Engineering. I also express my

sincere gratitude to our Principal Dr. M. Jagapathi Raju and Management members

of S.R.K.R. Engineering College (Autonomous) for providing me the facilities to

complete the Dissertation.

I am grateful to S.R.K.R. Engineering College (Autonomous) for giving the

opportunity to fulfill my aspirations and for successful completion of degree.

Last but not least, I express my heartful thanks to all my staff and friends for

their constant support, encouragement and valuable contribution in the completion of

this work.

PROJECT ASSOCIATES

Allu Venkata Nagababu

Kanuri Sumanth
Vuda Sai Kiran
Karri Rakesh
Viparthi Bhanu Teja
Kakamanu Sai Teja

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 ABSTRACT

High-strength copper alloys are used as materials for

injection molding tools or as cores and inserts in steel
molds because of their high thermal conductivity, corrosion
and wear resistance. Unfortunately, there is little
technological knowledge on the electrical discharge
machining (EDM) of Nimonic – 901 Alloy . In this work,
rough and finish machining conditions were tested using
copper and tungsten-copper as materials for the
electrodes. Cross-sectional micrographic and hardness
examinations as well as surface roughness measurements
were also carried out on workpieces after machining in
order to study the thermally affected zones. Appropriate
parameters settings for EDM of the investigated alloy are
suggested.

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 CONTENTS
Title

Certificate

Certificate of Examination

Acknowledgement

Abstract

Contents

CHAPTER 1

INTRODUCTION

1.1 Classification Of Machining

1.2 Conventional Machining

1.3 Non-Conventional Machining

1.3.1 Chemical Machining
1.3.2 Electro Chemical Machining
1.3.3 Ultrasonic Machining
1.3.4 Laser Beam Machining

1.4 Water Jet Cutting

1.5 Overview of Electron Discharge Machining
1.5.1 Types of Electro Discharge Machining
1.5.2 Machining Parameters of Electro Discharge
Machining
1.5.3 Die Electron Fluid of EDM
1.5.4 EDM Characteristics
1.6 Super Alloy

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 1.6.1 Chemical Development
1.6.2 Oxidation in Super Alloys
1.6.3 Super Alloy Processing
1.7 Nickel- Based Super Alloy
1.7.1 Machining of Nickel- Based Super Alloy

CHAPTER 2

LITERATURE REVIEW

2.1 Introduction

2.2 Literature Study

2.3 Summary

CHAPTER 3

EXPERIMENTAL INVESTIGATION

3.1 Introduction

3.2 Design Plan

3.3 Material Required

3.4 Experimental Plan
3.5 Machine Employed
3.5.1 Measurement of Surface Roughness
3.5.2 Measurement of MRR & TWR
3.5.3 Measurement of ROC
3.6 Experiment Data Acquired

CHAPTER 4

METHODOLOGY
4.1 Introduction
4.2 Regression
4.3 Analysis of Variance

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4.4 Taguchi Technique

CHAPTER 5

RESULTS & DISCUSSION

5.1 Introduction
5.2 Performance Evaluation of Copper Electrode
5.2.1 Material Removal Rate
5.2.2 Surface Roughness
5.2.3 Tool Wear Rate
5.2.4 Summary
5.3 Performance Evaluation of Graphite Electrode
5.3.1 Material Removal Rate
5.3.2 Surface Roughness
5.3.3 Tool Wear Rate
5.3.4 Summary
5.4 Comparative Analysis
5.4.1 Introduction
5.4.2 Material Removal Rate
5.4.3 Surface Roughness
5.4.4 Tool Wear Rate
5.4.5 Summary
CHAPTER 6
CONCLUSIONS & FUTURE SCOPE
6.1 Introduction
6.2 Machine Capabilities
6.2.1 Response Parameters
6.2.2 Type of Electrode
6.3 Prediction Capabilities

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CHAPTER 7
REFERENCES

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 CHAPTER-1
INTRODUCTION

Transformation of a raw material bulk into usable product i

manufacturing. This begins with identification of raw material followed
a product as per requirement and finally a series of machining processes
necessary sequence leads to evolution of a product.

1.1 CLASSIFICATION

Among the three steps involved in manufacturing process o

machining plays a key role in determining the quality and cost of produ
machining processes are classified into two types conventional and un
based on manufacturing style employed as shown in Fig.1.1

MANUFACTURING

PRIMARY METAL METAL SURFACE

SECONDARY
SHAPING FARMING JOINING FINISH
PROCESSES
PROCESS PROCESSES PROCESSES PROCESSES

CONVENTIONAL NON-CONVENTIO
MACHINING MACHINING

Turning
Threading MECHANICAL THERMO
CHEMICAL ELECTRIC
Knurling
Milling
Drilling PLASMA
Boring ULTRASONIC CHEMICAL
ARC
Planning MACHINING MACHINING MACHINING
Shaping (USM) (CHM) (PAM)
Slotting
ABRASIVE LASER
Sawing
JET BEAM
Broaching MACHINING
Hobbing MACHINING
(LBM)
Grinding (AJM)
Gear cutting ELECTRON
Thread cutting BEAM
MACHINING
(EBM)
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Now a day’s unconventional machining is predominantly used over conventional
counter parts relaying on the ease and precision capabilities. However, both the
machining techniques have their respective advantages and limitations that are
discussed in the following text.
In simple terms, conventional machining employs a hard material as a tool to
machine a relatively softer work piece. The distinction in hardness of tool & work piece
in conventional machining decides cost of product and machining time.
It is known that as distinction in hardness of tool & work piece decreases, the
product cost increases due to greater machining time requirement; and vice-versa. In
some cases conventional machining may not be feasible.
1.2 CONVENTIONAL MACHINING
In traditional processes, shear stress is used to fracture the material by
implementing stresses beyond ultimate stress of work piece. In order to obtain a desired
geometry the machine tools such as lathes, drilling and milling machines are used with
a sharp cutting tool for material removal. Here, the shear stress is responsible for
material fracture. In Conventional machining process the shape of the work piece is
changed by the cutting tool made up of hard materials, which means the work piece
material and the cutting tool are in physical contact with each other and the material is
removed in the form of chips. Traditional machining is also having so many
disadvantages compared with non-traditional machining such as tool wear, generation
of heat and low precision.
Conventional machining is not feasible due to increasing costs for machining
hard metals thereby increasing demand and energy. By comparison with recently
advanced methods, conventional machining is inappropriate method to machine
complex shapes of hard, high strength and high temperature resistant alloys and die
steels. It also results uneconomical due to higher tool wear and loss of production
quality due to induced residual stresses. The operations such as turning, drilling,
milling, grinding and broaching comes under conventional machining process.

1.3 NON-CONVENTIONAL MACHINING

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 Non-traditional manufacturing process can be defined as a group of machining
process which removes the unwanted material from the work piece by using
mechanical, thermal, chemical or electrical energy or by the combination of these
energies. In this process cutting tool is omitted. Difficult-to-cut materials, super alloys
& brittle materials are extremely hard to machine by traditional machining processes.
In such cases the un-conventional machining comes into play where the traditional
machining fails. Conventional machining processes are generally not feasible in special
cases like hard & fragile materials which are difficult to clamp flexible & slender work
pieces to produce parts which have too complex shapes. Non-conventional machining
offers many advantages compared to traditional manufacturing process when they are
properly employed.
A number of non-conventional processes are briefly described in this section. In
Conventional machining, the shearing phenomenon results in chip formation due to the
contact between the work piece and cutting tool. But in the Non-conventional
machining, the direct form of energy is used. Precise cut & surface finishing are
relatively poor in Conventional machining when compared to Non-conventional
machining process. The machining methods are grouped according to the fundamental
machining energy used i.e., by mechanical, thermal, electrical, chemical etc.
1.3.1. Chemical Machining
In Chemical Machining as in Fig. 1.2, by using a strong chemical reagent
etching is done on the work piece material by controlled dissolution. By immersing the
work piece in etchants or chemical reagents such as alkaline & acid solutions the
unwanted material can be removed. Same as in corrosion & chemical dissolution of
metal the material can be removed by microscopic electro chemical cell action. All the
exposed surfaces will be simultaneously etched even though the material removal rate
is 0.0025-0.1 mm/min.
It involves the chemical milling of contours, chemical blanking for etching,
chemical milling of pockets, Photochemical machining for etching. Weak chemical
reagents are used for deburring & chemical jet machining.

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 Fig. 1.2 (a) Schematic view of chemical machining process
(b) Steps for producing a cavity

(i). Chemical milling

Chemical milling (CHM) is the controlled chemical dissolution (CD) of a
work piece which is in contact with a strong reagent in order to produce pockets &
contours. The essential material utilised in CHM are etchant and maskant. Alkaline
solution and acids are the etchants used in appropriate ranges of temperature and
chemical compositions. The elastomeric products are properly designed to ready
stripping and are highly resistant to harsh etchants.
The process parameters involved in CHM are the type of reagent solution,
concentration, mixing, properties, circulation and operating temperature. All these are
having direct impact on work piece such as etch factor (d/t), etching and machining
rate, production tolerance and surface finish.
The steps involved in the CHM process:
 Preparation and pre-cleaning the surface of work piece.
 Masking is done by using readable strippable mask.
 Scribing of the mask, guided by templates.
 Etch factor should be taken properly which is the ratio of undercut (d) to the
depth of etch (t).
 The exposed surface of work pieces is then etched chemically.
 De-masking is done after machining process. (The parts are thoroughly washed
in order to prevent any further reactions.)

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(ii). Applications
 CHM has wide range of applications from Al alloy aeroplane wing parts to
minute integrate chips.
 It is used for the elimination of the decarburized layer from low alloy steel
forgings.
 Removal of sharp burrs from conventionally machined parts of complex shapes,
larger aircraft components, missile skin panels.

1.3.2 Electrochemical Machining (ECM)

Fig 1.3 Electro Chemical Machining process

On the basis of Reverse electro laying principle, the metal-removal is done in

ECM. In which the particles reach machined tool (cathode) from work piece (anode).
The depleted material carried away by the electrolytic fluid before it can reach the
machined tool. Here the produced cavity is treated as the tool shape’s female mating
image. A schematic view of Electro chemical machining process is shown in Fig 1.3.
Even the difficult-to-cut materials can be easily cut by ECM process. Complex
shapes can also be fabricated easily on the super alloys by ECM process. A low
voltage, high D.C current is passed in between the work piece and electrode where the
ECM tool is positioned very close to the work piece.
(i) Advantages of ECM
 The components which undergo ECM process are not subjected to
thermal/mechanical stresses.

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  Tool wear rate doesn’t occur during ECM process.
 Due to lack of stresses, the fragile parts can also be easily machined.
 The difficult to access areas of parts can also be easily deburred by the ECM
deburring process.
 Turbine blades, jet engine parts and nozzles in the aerospace industry which are
made of difficult-to-cut materials can be easily machined by ECM.
 Complex geometrical shapes on super alloys can be done by ECM.
 Deeper grooves in super alloys can be made by this process.

(ii) Limitations of ECM

 Sharp square corners/flat bottoms are not produced by ECM due to the
electrode tendency.
 It is only used primarily for highly specialized operations due to high equipment
cost even though it is applicable to most of the metals.

1.3.3 Ultrasonic Machining

A very high frequency mechanical motion and slurry of abrasive particles are
used in USM to create cavities, holes on brittle and hard work pieces by using shaped
tools. Brittle materials such as glasses, polycrystalline ceramics and single crystals can
be easily machined to provide work piece profiles and intricate shapes which are very
difficult to machine by conventionally machining process. The slurry which consists of
hard particles are accelerated towards the work piece surface by an oscillating tool with
a frequency up to 100 KHz through continuous abrasions, the tool creates a cavity of
cross-section identical to its own. A schematic view of ultrasonic machine tool is
shown in Fig. 1.4.

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 Fig. 1.4 Schematic view of ultrasonic machine tool
USM is majorly used to machine hard and brittle materials such as Boron
Carbide, Titanium Carbide, Quartz, Ceramics, and Rubies etc. This process can
effectively machine electrically conductive or insulating materials.
A very high wear resistant material such as high carbon steel should be used as
a machining tool. The slurry should contain abrasive like Silicon carbide, Boron
carbide and Aluminium oxide for effective machining operations using USM.
(i) Advantages
 As USM process is a non-chemical and non-thermal process, it doesn’t disturb
the microstructure of machined components and it also provides completely
stress-free machined surfaces.
 Electrically conductive and non-conductive materials can be machined by
USM.
 Higher structural integrity and good surface finish can be achieved for the parts
machined by USM.
 Hard and brittle materials can be easily and precisely cut by USM.

(ii) Disadvantages
 Unlike traditional fabrication processes USM has less MRR & high-power
consumption
 Tool wear rate is high in USM.
 USM has constraints regarding machining area and depth.

1.3.4 Laser-Beam Machining (LBM)

Laser-beam machining is a thermal material-removal process in which, by
utilizing a beam of high energy and coherent light, the particles are melted and
vaporized on the surface of work piece. Operations such as cutting, drilling, welding
and marking are done by using lasers. Laser-beam machining is an appropriate
machining process in order to obtain accurate hoes. The schematic view of LBM is as
shown in the Fig.1.5.

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 Fig. 1.5 Laser beam machining schematic view

(a) Laser beam cutting (drilling)

 In Laser beam drilling the melting takes place at the point of contact whenever
the energy transferred into the work piece via a Nd:YAG laser, that changes
into a plasma and leaves the area.
 A gas jet (suitably, Oxygen) can make this phase transformation easier and
departure of removed material.
 By comparing with other methods, Laser drilling is suitable for hard materials
and hole geometries.

(b) Laser beam cutting (milling)

 A laser spot is reflected on to the work piece surface can be directed though a
trajectory and cuts the material.
 Continuous wave-mode gas lasers are suggested for cutting which gives high-
average power, generating high MRR and good finished surfaces.

(i) Advantages of laser cutting:

 It can be suitable for cutting hard and abrasive materials.
 The process is flexible and cost effective.
 It is also used for cutting sticky materials.

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  There is no tool wear.
 Lubrication is not required.
 Accuracy is very high.
 Limited heat effected zone.
 As the laser point moves in any path, there is no limit to cutting path.
 By allowing very fragile materials for laser cutting the process is stress less
without any support.

(ii) Limitations of Laser cutting:

 Capital investment is very high.
 It is uneconomical and it requires the assist or cover gas.
 Maintenance cost is very high.
 Because of taper it involves thickness limitations.

1.4 Water Jet Cutting

Water jet cutting is cost effective and accelerating process by terminating or
diminishing the expensive secondary machining process. It is an appropriate process
for cutting a various type of materials by using high pressure jet of water or water
mixture and abrasive particles. Here, heat is not applied on the materials so that the
cutting edges are sharp with minimum burr. In this process the defects like
crystallization, reduced weldabilty, hardening, cracked edge defects and machinability
are reduced.

Fig. 1.6 Schematic representation of Water jet cutting

The basic principle involved in this process is pressurizing of water to very high
pressures and enable the water to run off through a very small path called jewel/orifice
(Fig. 1.6). It can use the water beam departing the orifice to cut soft materials. This
process is not applicable for cutting hard materials. The inlet water is pressurized in

xvii
between 1300-4000 bar. High pressure is forced from the jewels small hole, which is in
0.18 to 0.4 mm in diameter. Water jet cutting is used during fabrication of machining
parts.
(i) Advantages of Water jet cutting
 There is no heat effected zone and no hardening which is especially used for
cutting various metals and alloys without distorting or warping, melting them.
 It can’t produce hazardous gases and dust particles which are harmful if inhaled
(i.e., environmentally friendly).
 It has an ability to cut in any direction (i.e., Omni-directional cutting).
 It is a flexible manufacturing process.
 It is able to cut reflective materials and fibre-reinforced particles, stacked and
uneven surfaces of different materials.
 It can save raw material (small cutting kerf width and capability of nesting).

(ii) Disadvantages:
 It is uneconomical and inaccurate to cut thick parts.
 It is uneconomical for mass production.
 While cutting highly thick materials taper arises, this causes dimensional
inaccuracy.

1.4.1 Abrasive water jet cutting

Abrasive water jet cutting is an extension of water jet cutting which contains
abrasive particles such as silicon carbide or aluminium oxide in the water jet to increase
the rate of material removal more than water jet machining. This process is used to cut
any type of material ranging from hard brittle materials such as glass, metals and
ceramics to very soft materials such as rubber and foam. The computer operated control
and wide cutting stream enables this process for obtaining efficient & accurate parts.

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 Fig. 1.7 Schematic representation of Abrasive water jet cutting
Abrasive water jet cutting is an ideal process for cutting the materials which
can’t be cut by thermal or laser cut. This process is also applicable for cutting various
thickness materials of metallic, non-metallic and advanced composites. It is much
suitable for cutting heat sensitive materials which can’t be machined by the other
processes that produces heat during machining.
Fig.1.7 seems to be identical to water jet cutting, but some structural
modifications beneath the orifice; such as guard, abrasive and mixed tube. Vacuum is
created when the high velocity water is coming out of the jewel and the abrasive
particles are sucked from the abrasive line which is mixed in the mixing tube to form a
high velocity beam of abrasives.
Abrasive water jet cutting is highly applicable in aerospace, electronics and
automotive industries. In aerospace industry, Abrasive water jet cutting is used for
machining the engine parts (Aluminium, Titanium, and hard resistant alloys), titanium
bodies for military aircrafts, Aluminium body components and interior cabin
components. In automobile industry, parts such as interior trim (trunk lines, headlines
and door panels) bumpers, glass body parts are machined by using this process. In the
same manner, cable stripping and circuit boards are machined in electric industry by
using Abrasive water jet cutting.
(i) Advantages of Abrasive water jet cutting
 It can leave a satin smooth surface finishing, thus no further finishing required.

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  No generation of heat.
 Clean cutting process without slag or cutting dross.
 Terminates thermal distortion.
 Low cutting forces are required on work piece material.
 No cutter induced distortion and metal contamination.
 Small cutting kerfs reduce the wastage of material.
 Surface finish of 125-250 microns.
 No cutting burr.
 It won’t produce hazardous and dust particles which are harmful if inhaled (i.e.,
environmentally friendly).

(ii) Limitations of Abrasive water jet cutting

 It is uneconomical for larger production rates.
 It can reduce rate of cutting.
 It can’t cut materials which degrade with moisture.
 High noise levels occur during operation.
 It can’t achieve good surface finish at high cutting speeds.
 This is not suitable for rough cutting.
 High capital investment.

1.5 OVER VIEW OF ELECTRON DISCHARGE MACHINING (EDM)

Joseph Priestly in the year 1770 has studied the effect of erosion by electrical
discharges however; it came into existence in 1943 when two scientists B.R. Lazarenko
and N.I. Lazarenko discovered the EDM machine. They created a controlled process of
machining the materials into required shapes by using the erosion effect of electrical
discharges. In the EDM process, an electric spark is generated between the work piece
and electrode which are separated by die electric fluid. As the voltage between the
work piece and the electrode increases, the intensity of the electrical field between the
electrode and the work piece increases rapidly and breaks down the strength of die
electric fluid which allows current to flow between the electrodes.
In the recent years, EDM is prominently used in the machining of high
strength, temperature resistant alloys and difficult-to-cut materials. A spark gap of
0.015 mm is maintained between the electrode and work piece. In which the electrode
acts as cathode and the work piece acts as anode. Both the electrode and the work piece
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are submerged in the die electric fluid. An immense pressure is developed in between
the work piece and the electrode due to high intensity sparks and as a result high
temperature is reached which melts down and erodes the material from the work piece.
Material Removal occurs due to instant vaporization and melting of material.
The molten metal is removed partially but not completely with the withdrawal of
potential difference. Whenever the plasma channel collapses, the pressure (or) shock
waves is generated by evaluating molten metal to form a crater of removed material
around the spark area.
1.5.1 Types of Electro Discharge Machining
(i) Die-sinking EDM and
(ii) Wire-cut EDM

(i) Die-sinking EDM

Fig. 1.8 Die-Sinking EDM

Die-sinking Electro Discharge Machining process is also known as volume
EDM or cavity type EDM process in which the electrical potential is generated in
between the two metal parts by the power supply. In Die-sinking Electro Discharge
Machining (Fig.1.8) process consists of a work piece and electrodes which are
submerged in an insulating liquid (usually oil and less frequently die electric fluid).
Here the work piece and electrode are connected to a source of power supply and are
separated by a spark gap, electric tension is created between them and sparks are
created, which melts down the metal.

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 In Die-sinking Electro Discharge Machining process the two metals in
conjunction with an insulating liquid are attached to a source of current which can
operate automatically based on the setting parameters on the controller.
Whenever the electrode comes towards the work piece, the dielectric breaks
down in the dielectric fluid to form a plasma channel and then a small spark jump.
These sparks generally strike only once at a time because most of the location in the
inter electrode space are having similar local electrical characteristics which enables the
spark to occur simultaneously at different locations, in which the sparks occur in huge
number at seemingly different places in between the work piece and electrode. When
the erosion takes place in the base of the metal the spark gap is increased subsequently
and electrode is lowered automatically by the EDM machine, so that the process can be
continued uninterruptedly. Several lakhs of sparks will be occurring per every second
but the set-up parameters will be carefully monitored by the duty cycle.
(ii) Wire cut EDM
The wire cut Electro Discharge Machining is also known as Spark Electro
Discharge Machining in which a single-strand thin metal wire (generally brass)
merging with de-ionized water is used to conduct electricity that allows the wire to cut
through the metal by using the heat obtained from electrical sparks. The Schematic
view of Wire Cut EDM is shown in Fig.1.9.

Fig.1.9 Wire Cut EDM

The electrified current is discharged in this process by means of a taut thin
wire (cathode) and is guided along the cutting path. This process is suitably applicable
for cutting the plates as thick as 300 mm and for making punches, tools and dies from
hard metals which are to be very difficult to machine with other methods. As the wire

xxii
cut Electro Discharge Machining process doesn’t require high cutting forces for
material removal, it is used when low residual stresses are required. The wire in the
WCEDM process emits sparks on different sides, which shows the wire is thinner than
the cut. In the finishing process, the mechanical properties of a material are changed
due to less residual stresses whenever the power or energy is low relatively. The wire
cut Electro Discharge Machining process can be used to machine complex parts and
precision components due to its inherent properties.
1.5.2 Machining parameters of Electro Discharge Machining
(i) Discharge current:
Discharge current is proportional to MRR. The current is measured in
amperes.
(ii) Pulse on-time:
The period of time for which the current flows per cycle is known as Pulse on-
time. During this pulse on-time the quantity of energy applied is directly proportional
to material removed. Here the energy is completely controlled by the peak current and
the length of the pulse on-time.
(iii) Pulse off-time:
The period of time in between the sparks is known as pulse off-time. In which
the molten metal is allowed to solidify and washed out of the arc gap. This is the only
parameter which affects the speed and the stability of cut. It is clear that if the pulse off-
time is very short, the sparks are unstable.
(iv) Flushing Pressure:
It is used to flush the eroded material from the work piece during machining.
Improper flushing leads to poor surface finish due to the formation of pokes, voids on
the machined surface.
(v) Arc gap:
During the Electrode Discharge Machining process, a small gap is maintained
in between the work piece and electrode known as arc gap which is also termed as
spark gap. Servo systems are used to maintain this spark gap.
(vi) Duty cycle:
The percentage of pulse on time with respect to the total time of the cycle is
known as Duty cycle. This is obtained by the ratio of pulse on-time to the total cycle
time.

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(vii) Voltage:
Voltage is a potential that effects the MRR allowed per cycle which is
measured in volts.
1.5.3 Die electric fluid of EDM
Because of melting and thermal evaporation, the material removal takes place.
The process is controlled and the oxidation is avoided only by using thermal processing
which can be carried out in the absence of oxygen.
The functions of dielectric fluid are as follows:
 It is used for lubrication (i.e., cooling the electrode and work piece) and it
enables the arcing to be prevented.

 It serves as a conductive medium by ionizing and initiates the discharge and the
spark is conveyed.

 It is used for concentrating the energy in a very small region.

 It can be treated as coolant for quenching the sparks.

 It is used to carry out the metal eroded from the work piece.

The dielectric fluid used in electrode discharge machining is usually on

transformer on silicon oil, paraffin oil (kerosene), EDM oil, and de-ionized water.
1.5.4 Electrode material of Electro Discharge Machining
The electrode material is selected such that, whenever it is impinged by
positive ions it won’t undergo much tool wear. By tailoring and choosing the
appropriate electrode properties the rise of localized temperature is minimized. The
electrode should be easily workable for machining intricate shaped geometric features
in Electro Discharge Machining.
The main features of electrode material are
 High electrical conductivity

 High density

 High thermal conductivity

 High melting point

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 MRR, TWR and other characteristics of operation are influenced by dielectric
fluid. The different electrode materials which are used most commonly in an industry
are Copper, Graphite, Tellurium copper, Brass.
1.5.5 Electro Discharge machining characteristics
Irrespective of the type of electrode material and dielectric fluid used, the
EDM capability is calculated based on the following scenario.
 Material removal rate (MRR)

 Tool wear rate (TWR)

 Surface Roughness (SR)

 Radial Overcut (ROC)

The maximum MRR indicates better efficiency and economical regarding

Electrode Discharge Machining process but increasing of MRR is not always desirable
in every application because it sacrifices the work piece integrity. The MRR value can
be calculated by using the below equation 1.1.
V
MRR = ( mm3 /min) 1.1
t
Where V is the volume of material removed and t is the machining time.
The TWR also termed as tool wear rate which is not a desirable parameter
during machining of EDM as it affects the dimensions of the tool electrode used which
results in uneven cutting of work piece material. The TWR value can be calculated by
using the below equation 1.2.
E b−E a ( g)
TWR= 3
( mm3 /min) 1.2
t ( min )∗density ( g/mm )
Where  Eb  and  Ea  are the weights of electrode material before and after
machining, respectively, and t is the machining time.
Generally, an EDM machined surface consists of craters, globules, pockmarks,
voids, pores, cracks and uneven fused structures, which create unevenness of surface
area which is termed as Surface roughness. In machining process Surface Roughness
represents the index of product quality. The performance of mechanical components
and their life time & production cost are influenced by SR because it can affect some
characteristics such as Electrical & Thermal conductivity, ease of lubricant holding,
friction and geometric tolerances etc. Surface Roughness is used to measure the finer

xxv
irregularities in the surface texture in order to achieve the desired surface quality of
functional part.
Radial Overcut is the variation in machined cavity size to the size of electrode
used. It severely affects the dimensional accuracy of the component and becomes
significant when tolerance requirements are needed in the industries like Aeronautics
and nuclear.
A detailed distinction between conventional and non-conventional machining
processes is presented here in Table 1.1.
Table 1.1 Comparison between Conventional and Non-Conventional Machining
processes

S.No. Conventional Machining Process Non-Conventional Machining Process

Material Removal takes place either

by chip formation or no chip
formation. In ECM process, the
Material Removal occurs with
material is removed by
1. macroscopic chip formation by shear
electrochemical dissolution at atomic
deformation.
level where as in Advanced Jet
Machining process, the material is
removed by microchip formation.
In this process presence of physical
It requires the presence of physical
2. tool is not necessary. Laser beam is
tool as in a Lathe.
used during machining in LJM

xxvi
 In Non-Conventional Machining
process, it is not necessary to use
mechanical energy to provide
material removal because they can
In Conventional Machining process use different domains of energy in
mechanical energy by the application order to provide material removal.
3.
of cutting forces is used to provide USM, WJM and AJM machining is
material removal. done by using mechanical energy.
However, in Electro Chemical
Machining process, material removal
takes place by electro chemical
dissolution.
It requires direct contact of the tool There is a gap in between the tool
4.
and work piece. and work piece.
5. Surface finish is low. Surface finish is generally very high.
6. Accuracy is low. Accuracy is high.
These are economically applicable These are not economically suitable
7.
for all types of materials. for all the materials.
They are inefficient and
These are applicable for the
8. uneconomical while producing the
production of prototype parts.
prototype parts.
Higher wear rate leads to wastage of Because of low wear/no wear
9.
material. material is not wasted.
They can cause sound pollution They won’t cause any sound
10. because these are mostly noisy pollution because these are quieter
operations. operations.
11. Capital investment is low. Capital investment is high.
Equipment set-up/arrangement is Equipment set-up/arrangement is
12.
easy. complex.
They require skilled or unskilled
13. They require skilled workers only.
workers.
Conventional Machining is operated Non-Conventional Machining is
14.
manually. mostly fully automated.

xxvii
1.6 SUPER ALLOY

A super alloy is a high-performance alloy which is having special features

such as high mechanical strength, excellent surface stability, thermal resistivity to
deformation of creep and resistance to oxidation & corrosion. The arrangement of
atoms, ions or molecules in a super alloy is usually face centred cubic austenitic crystal
structure. Some of the examples for super alloys are Hastelloy, Rene alloys, Incoloy,
Inconel, Haynes alloys, TMS alloys, Waspaloy, MP98T and CMSX single crystal
alloys.

The development of super alloy depends on both chemical and process

innovations. In which precipitation strengthening is the major strengthening mechanism
that can establish secondary phase precipitates such as γ' (gamma prime) and carbides.
The resistance to oxidation & corrosion can be achieved by the elements like
Chromium & Aluminium. The major applications of super alloys involve turbine
engines, both in the marine and aerospace.

1.6.1 Chemical development

The properties of Nickel based super alloys can be altered to some extent by
the addition of some common exotic metals. The general alloying additions used are
molybdenum, titanium, zirconium, carbon, boron or hafnium, rhenium, vanadium, iron
etc. Creep resistance is responsible to slow down the dislocation motion in crystal
structure. In the Nickel based super alloys γ-Ni3 (Al, Ti) will help in obstructing the
dislocation motion.

The strength of super alloys is drastically increased due to high volume

fractions of γ-intermetallic phase. The γ-phase nature is modified by precipitation
strengthening heat treatment and the chemical addition of Ti, Al will promote the γ-
phase. In the primary phase super alloys are obtained by the use of double phase heat
treatment which creates a dispersion of Cuboidal γ-particles. Oxidation resistance of
super alloys is increased by the addition of B, Y and Cr etc. An oxide layer is formed
on the super alloy due to the addition of Al, Cr to prevent oxidation. This oxide layer
sticks to the surface more precisely due to the addition of B and Y.

xxviii
1.6.2 Oxidation in super alloys

The oxidation in super alloys which are exposed to corrosive environment and
operated at high temperature is paramount concern. In the oxidation process a new
oxide phases are formed due to the reaction of oxygen with the alloying elements.
Oxidation degrades the alloys in different ways if unmitigated. They are

 The corrosion takes place in alloy over time including sequential oxidation,
cracking and spalling of surface.
 By the introduction of oxide phases the surface of the metal is embrittled that
may promote crack formation and fatigue failure.
 Depletion of the alloying elements affects the super alloys by changing its
mechanical properties and compromising its performance.

In order to avoid these deleterious processes a special strategy which is used

initially is known as selective oxidation. A specific oxide phase is designed for the
alloy by the proper ratio of alloying elements which acts as a barrier to the oxidation. In
most of the cases Cr and Al are used to form suitably continuous and thin oxide layers
of Chromia (Cr2O3) and Alumina (Al2O3).

The selective oxidation offers the protective effect that can be eroded by the
numerous mechanisms. As a result of the kinetics of oxidation the continuity of thin
sacrificial oxide layer can be disrupted or that can be compromised due to stress. The
effectiveness of the layer which acts as diffusion barrier to oxygen can be nullified
when the layer is discontinuous. The oxide layer stability is also influenced by other
minor elements present in it. Elements such as Si, B & Yttrium which are added to the
super alloys improve the adhesiveness of oxide layer, reducing spalling and to maintain
the integrity of the protective oxide layer.

From the experiment, it can be observed that oxidation is the only basic form
of chemical degradation in super alloys. When the reaction takes place with salts and
sulphur compounds or some other chemical conditions which dramatically changes
with time, more complex corrosion process occurs. These problems and the issues of
basic oxidation process can be overcome through thin coatings.

xxix
 1.6.3 Super alloy processing
Super alloy processing is used to create various materials for different portions
of a jet turbine engine. The super alloy processing has lead to the increase of operating
temperatures in Super alloys. Super alloys were primarily iron based or cold wrought
before 1940’s. The operating temperatures are raised in a significant manner by the
investment casting of Co base alloys in 1940’s. The chemical composition of super
alloys is strictly controlled by the vacuum melting developed in 1950’s which can
allow reduction in contamination that leads to a revolutionary change in processing
techniques such as directional solidification of alloys & single crystal super alloys.
Inconel alloys are high resistant materials to oxidation and corrosion to
withstand heat and pressure. In order to protect the surface from further attacks during
heating, Inconel creates a stable, thick and passivating oxide layer on its surface.
Inconel holds its strength over wide ranges of temperature and is suitable for high
temperature applications. At high temperature, the strength of the Inconel alloys is
developed by solid solution strengthening and precipitation hardening. So that Inconel
alloys are mostly suitable for high temperature applications. The industrial names for
Inconel alloys include Inconel 625, Altemp 625, Nickelvac 625, Chronin 625, Haynes
625, Inconel 600 & Inconel 713.
Solid solution strengthening is an alloying process which is used to improve
strength of a pure metal. In which the atoms of one element are added to crystalline
lattice of other element. The solid solution is formed by the alloying element by
diffusing into the matrix. In the same manner a second phase will be formed in most of
the binary systems which can be alloyed above a certain concentration. Thus inter
metallic is the equivalent or similar branch of metallurgy.
Precipitation hardening is a process of heat treatment which is used to increase
the yield strength of malleable metals that may include structural alloys of Al, Ni, Mg,
Ti and stainless steels. This is also known as Age hardening. In case of super alloys it is
used to cause peculiar yield strength by providing very high temperature strength. In
order to produce fine particles of an impurity phase, Precipitation hardening relies on
changes in solid solubility with temperature, which can prevent the movement of
dislocations or defects in crystal lattice. The dislocations are usually the most frequent
carriers of plasticity. In solids precipitation is used to produce different particles of
various sizes which are having different properties. In order to allow the precipitation,

xxx
the alloys should be kept at an elevated temperature for a long time period. This delay
time is known as Aging.
It is to be noted that, Solution heat treatment and precipitation heat treatment
are the two extreme heat treatment processes which can involve precipitates and alter
the material strength. A single-phase solid solution is formed by solid solution
strengthening through quenching where as in precipitation hardening the impurity
particles are added to increase the strength of the material. Inconel alloys are highly
resistant materials to oxidation & corrosion at high pressure and kinetic energy. In
order to protect the Inconel surface from further attacks heating is done. Inconel is
having high strength at a wide range of temperature that shows it can be suitable for
high temperature applications where as Steel & Aluminium are fail to resist creep
because of thermally induced crystal vacancies. In the process of age-hardening less
amount of Niobium reacts with Nickel to form gamma prime or Ni3Nb. A very small
cubic crystals formed by γ' can inhibit slip & creep at elevated temperature effectively.
The γ' crystals formation increases with time (i.e., for every 3 hours of heat exposure of
850°C and it continues to form after the exposure of 72 hours).
By using traditional methods, it is difficult to machine and shape Inconel
material due to rapid work machining. By finishing the first pass of machining, work
hardening tends to deform plastically either by the tool or work piece on subsequent
passes. Age hardened Inconel can be machined by the use of an aggressive hard, but
slow cutting tool which minimizes the total number of required passes.
The full aging Inconel 718 threads can be machined by rolling and using
induction heat up to 740°C. The internal threads in the holes can be made by thread
milling. They can also be done by the use of a Die sinking EDM, whereas the plate
cutting can be done by a water jet cutter. Nickel alloys can be machined by using new
whisker reinforced cutters. Here the Material Removal Rate is mostly 8 times quicker
than the carbide cutters. Apart from these methods, a selective laser melting can also be
used to machine Inconel parts.

xxxi
1.7 NICKEL-BASED SUPER ALLOY
 Gamma (γ)

This is the phase which comprises the Ni-based super alloy matrix. It is
a solid solution face centred cubic austenitic phase of alloying elements.
Carbon, Molybdenum, Chromium, Tungsten, Iron, Niobium, Titanium,
Vanadium, Aluminium and Tantalum are the alloying elements found in Ni-
based alloys. In the process of formation of these materials carbides starts to
participate as the Nickel alloys are capable due to melting even at low phase
precipitates.
 Gamma prime (γ')

This phase comprises the precipitate which is used to strengthen the

alloy. It can be called as inter metallic phase based on Ni 3 (Ti, Al) having an
ordered FCC L12 structure. Gamma prime is analytic with the super alloy
matrix that can have lattice parameters which varies around by 0.5%. Ni (Ti,
Al) are controlled systems having Ni atoms situated at cube phase whereas Al
or Ti atoms are present at the cube edges. As the Gamma prime particles
precipitates aggregate, their energy states are decreased by arraying in 100
directions in order to form cuboidal-structures. It has the chance of instability at
600-850°C in which Gamma prime transforms as HCP η phase, below 650°C
temperature γ' is used for strengthening.
 Gamma double prime (γ")

It is having a composition of Ni3Nb or Ni3V and it is used for

strengthening Ni based super alloy at low temperature (below 650°C). Gamma
double prime (γ") is having BCT crystal structure. Due to the mismatch of
lattice anisotropic discs are formed in between the precipitate of BCT and FCC
matrix which leads to high strains along with order hardening constitutes
primary strengthening mechanisms. The Gamma double prime is unstable at
temperature above 650°C.

xxxii
  TCP (Topologically Close-Packed Phases):

This TCP phase is related to a member in a family of phases which cannot be

automatically close-packed and having close-packed phases with HCP stacking. These
phases are characterized by depleting the γ-matrix of strengthening; a solid solution
refracting element which includes Cr, Co, W, and Mo. Due to kinetics of long-time
durations, these phases are formed at elevated temperatures greater than 750°C.
Ni based super alloys are suitably used to make the components in aircrafts and
gas turbine engines. Due to their high mechanical properties they can be operated at
elevated temperatures. The components used in aerospace suffer due to high
temperatures, pressures, and velocity. It is also necessary to have the strongest controls
for machinery. Due to the necessity of reliability in the manufacturing of aerospace
components it needs to maintain high quality.
In the manufacturing process of aerospace components, it is mandatory that
each part will be made with precession whether it is complex task or not. In which due
to high cost factor of material, the cost of scrap is high and it is necessary to minimize
the waste strictly. As the Nickel based super alloys are most expensive and difficult-to-
cut, the components are machined by using these alloys by taking proper care and
keeping required quality characteristics. Irrespective of all these risk of failures by
fatigue or fracture the components are fabricated from super alloys having highest
integrity.
1.7.1 MACHINING OF NICKEL-BASED ALLOYS
In machining of Nickel-based alloys, the developing pressures can produce a
hardening effect that delays the further machining process. It leads to distortion in
components having lower cross section. By choosing the machining practices carefully,
the effect of work hardening can be minimized. The rates of feed and radial overcut are
the factors sufficient to avoid burnishing and glazing. Due to inappropriate clearance or
dwell in cut, the tools must not be allowed to get in contact with the work. Even though
the machining conditions are optimized, some of the stresses which cause successive
distortion of the work are raised. For acquiring good dimensional accuracy and
stability, the component will be rough out as per the size and later the finishing
operations are carried out to the exact size. This mechanism relieves the stresses on the
work piece to a large extent. The mechanical properties of a part are affected by stress
relieving where as its dimensions are little bit effected.

xxxiii
 The microstructure of the component affects the machinability of alloys in two
paths:
 Machinability is improved by the presence of sulphide or graphite phases.
 Hard phases like carbides, carbonitrides, silicates, nitrides, oxides, and possibly
the phases (Ni3 (Al, Ti)), are abrasive causing rapid tool wear.
The Nickel-based alloys are classified into four groups. They are Group-A, Group-
B, Group-C and Group-D as shown in the below Fig.1.10.

Classification of Nickel-based alloys

Group A Group B Group C Group D

Nickel 200 Monel 400 Nickel 270 Monel K-500

Nickel 201 Monel 401 Monel K-500 Inconel 617
Nickel 205 Monel 450 Inconel 600 Inconel 625
Nickel 212 Ferry alloy Inconel 601 Inconel 706
Nickel 222 Nilo alloy 36 Inconel 690 Inconel 718
Nilo alloy 48 Nimonic 75 Inconel 751
Nilo alloy K Nimonic 86 Nimonic 90
Inco alloy Incoloy 800 Nimonic 105
MS 250 Incoloy 802 Nimonic 115
Incoloy 825 Nimonic C-263
Incoloy DS Nimonic 901
Nimonic PE11
Nimonic PE16
Nimonic PK50
Hastelloy
Rene 41

Fig. 1.10 Classification of Super Alloys

In Group-A most of them are Nickel-based alloys which are having modest
mechanical strength and high toughness. These are generally hardened by cold works.
They are utmost gummy in the normalized and hot worked condition. In which cold-
drawn material is the most preferable one for good machinability and high surface
finish. These alloys are used in machining electronic parts and high corrosion resistance
applications such as tackling alkaline solutions and food items.

xxxiv
 In Group-B most of them are nickel-copper alloys which are having high
strength and low toughness when compared to Group-A. These are generally hardened
only by cold work. The machinability and surface finish are improved by using stress
relived material. These alloys are used for different fixtures in the piping systems for
sea water applications.
In Group-C most of them are solid solution Ni-Cr and Ni-Cr-Fe alloys that are
similar to austenitic stainless steels. These are usually hardened only by cold work and
are machined at cold drawn or cold drawn & stress relieved conditions. These alloys
are used in aircraft engines for making combustors, ducting and exhaust systems, thrust
reversers, hush kits and after burners etc.
Group-D consists of age hardened alloys divided in to two sub groups.
 Unaged condition alloys.
 Aged condition alloys & some other alloys in both aged & unaged condition

In Group-D the alloys are having high strength and hardness mainly aged ones.
The materials which are annealed and quenched or air cooled rapidly are in a soft
condition and are easily machined. Due to this softness unaged condition is required for
achieving higher ease in drilling, threading and tapping. Whether the age hardened
alloys are neither solution annealed or hot worked and quenched, they are having high
machinability.
Super alloys are having a matrix with austenite FCC structure. The performance
of super alloys at high temperature is distinguished in terms of their tensile strength, hot
hardness, resistance to corrosion and creep. They are operated at a temperature of
1100°C. In aerospace industrial gas turbines and marine turbines these metals are
extensively used, e.g. for blades of turbine in jet engines, seals, rings, fasteners, discs of
engine, shafts, bimetallic engine valves, automotive applications and nuclear power
plants. Fig. 1.11 illustrates a typical Casing in an aircraft engine made up of Nimonic-
901 super alloy.

xxxv
 Fig. 1.11 Typical Aircraft Engine

CHAPTER-2
LITERATURE REVIEW
2.1. INTRODUCTION
The difficulty associated with conventional machining process during
transformation of a hard material bulk in to finished product, strengthened the necessity
and use of various unconventional machining techniques. While, high strength and high
hardness materials like Ni-Cr alloys are predominantly used to meet current
engineering challenges. In this conjunction, an explicit literature survey is performed to
review the unconventional machining techniques especially, Electrical Discharge
Machining and novel Ni-Cr alloys that are capable of answering future challenges.
2.2. LITERATURE STUDY
M. S. Sohani et al. [1] discussed the significance of shape of the electrodes on
MRR and TWR along with the effects of various input parameters on MRR and TWR.
Rachid M’Saoubi et al. [2] discussed the recent advances in machining process & the

xxxvi
need for development for machining process for the newly developed aerospace
materials. Niraj Kumar Ohdar et al. [3] analysed the relationship between various
parameters and found out that for obtaining high MRR the significant factor is Pulse on
time and for low TWR is peak current.
Tiago Czelusniak et al. [4] surveyed articles on electrodes that can be used in
Die Sinking EDM and proposed the parameters required to select them. Rama Bhadri
Raju Chekuri et.al. [5] used MINITAB & Taguchi for design of experiments and
ANOVA for analysing the results and concluded that all the output parameters are
greatly influenced by current while Surface roughness is greatly influenced by Pulse on
Time for machining Nimonic C-263 super alloy. Mithilesh K. Dikshit et al. [6]
mmachined Inconel 265 on Die Sinking EDM using RSM and MINITAB for DOE, the
results were analysed using ANOVA and optimized using RSM and concluded that PC
is the most dominating factor for MRR and Pulse on Time for SR.
Modi, M et al. [7] have analysed the effects adding powders of different sizes
and volume in the dielectric fluid of PMEDM on MRR and SR and concluded that for
the same size and volume Copper powder gives the best MRR compared to aluminium
and chromium powders but results in poor Surface Finish. S. Ganapathy et al. [8]
analysed the process parameters of machining EN 8 steel using Copper electrode on die
sinking EDM using both RSM and ANN and found out that RSM model has more
precision than ANN model.
Deepti Ranjan Sahu et al. [9] studied the effect of different powders in
dielectric fluids in machining of Nimonic 263 super alloy using copper electrode on
PMEDM and concluded that due to addition of powder surface finish is improved. S.
Jeavudeen [10] Conducted experiments on die sinking EDM using various additives of
different sizes in dielectric fluid and concluded that the addition of powders in the
dielectric fluid has a significant impact on MRR & TWI.
Die sinking EDM process of shaping a Nickel-Chromium alloy called Inconel
718 is studied by Pushpendra et al [11]. The input parameters like current, pulse-on-
time along with electrode lift time and flushing pressure are observed over performance
parameters like MRR, SR & TWR. A Taguchi array is used for experimentation. Every
performance indicator is noted to vary significantly with discharge current and Pulse-
on-time while, duty cycle and tool electrode lift time possessed intangible influence
according to experimental and ANOVA analysis.

xxxvii
 Ulutan & Ozel [12] carried out state-of-art investigation on machining of
aircraft structural and engine materials like Titanium and Nickel alloys. Numerous
aspects of surface integrity like white layer thickness, residual stresses, microcracks,
work hardening aspects and surface roughness are discussed in detail. However, the
review showed-up on conventional machining techniques like turning, milling etc.,
where physical contact is established between tool and the work-piece. They also
discussed the empherical, analytical and finite element modelling based approaches
summarising huge data on Titanium and Nickel based alloys.
A novel additive mixed electric discharge machining (AEDM) is investigated
by Anil Kumar et al [13]. The AEDM technique in the studied uses Aluminium
powder with different mesh size. The influence of additive powder mesh size and
concentration are studied with respect to machining characteristics of Inconel 718
Nickel based super alloy. One variable at a time (OVAT) approach is used to study
MRR, SR & wear ratio (WR). Among which, 325 mesh size of aluminium powder with
6 gm/lit concentration revealed maximum machining rate, minimum SR. However,
least WR is achieved at 4 gm/lit concentration. Increasing the mesh size leads to
increase in Spark gap size and highest Spark gap is achieved at 325 mesh size thus, as
result of proper Spark gap leads to Superior flushing and machining conditions.
Ezilarasan et al. [14] studied machining performance parameters of Nimonic
C-263 super alloy using whiskers reinforced ceramic inserts during turning operation.
Taguchi experimental design considering cutting speed, feed rate and depth-of-cut as
input parameters and cutting force, tool wear and surface roughness as output responses
are investigated. Feed rate is observed to greatly influence cutting force, surface
roughness and flank wear. While depth of cut also contributes to flank wear
significantly than cutting Speed. The desirability function approach for multi response
Optimisation showed 210 m/min cutting speed, 0.5 mm/rev feed rate and 0.5mm depth-
of-cut as best combination.
In addition to regular performance parameters like MRR & EWR, form
tolerance and orientation tolerance of Inconel 718 super alloy is studied by
Dhanabalan et al. [15] using copper electrodes during EDM. Square and hexagonal
contoured electrodes are employed during EDM. The optimal multiple response
characteristics for square electrode are 12 Amp peak current, 600 μs of Pulse-on-time
and 10 μs of pulse-off-time. While for a hexagonal electrode, peak current of 12 Amp
followed by Pulse-on-time 400 μs and 40 μs of Pulse-of-time are observed as optimal
xxxviii
parameters. The form tolerance and orientation tolerances are observed to be within
acceptable range. A similar investigation is conducted by Ahmad & Lajis [16] at
higher peak currents to study and Correlate the input parameters with output responses.
Uhlmann & Domingos [17] research on developing and optimizing of EDM
Technology has shown a phenomenal result i.e., a drop of 50% in machining time.
There suggested technology possessed 21.9 minutes of total machining time against 48
minutes of turbine manufacturer. The Nickel-Chromium alloy considered in the
research is MAR-M247 using graphite electrodes. An average surface roughness
measured was below 6.3 μm while no cavities and cracks were noted from SEM
analysis.
Ezilarasan et al. [18] extended his previous investigation of machining
Nimonic C-263 super alloy using whisker-reinforced ceramic inserts during turning
process. This time a detailed microstructural study is carried out on Nimonic C-263
which include energy dispersive spectroscopy, scanning electron microscopy, X-ray
diffraction and Vickers micro hardness test. Cutting speed and cutting time are noted as
dominant factors influencing magnitude of residual stresses, while no evidence is
observed regarding decrease in work hardening and thermal relaxation during high
cutting speeds.
Tool wear characteristics in machining of Nickel based super alloys are
summarised through state-of-the-art review by Zhu et al. [19]. However, his review
includes various aspects of conventional turning process identifying the bottlenecks and
suggesting innovative advanced monitoring procedures to surpass machining
constraints during applicability of Nickel based super alloys.
Mohanty et al. [20] investigation focuses majorly on optimization of
machining characteristics of Inconel 718 during die sinking EDM process. A Box-
Behnkin design of response surface methodology is employed to collect data and a
multi-objective Particle Swarm Optimisation is carried out on regular process variables
like open circuit voltage current, Ton, duty factor and flushing pressure. Surface
roughness and MRR response parameters are studied. Unlike Inconel 725, Aveek et al.
[21] studied the machining characteristics of Inconel 825 considering L9 orthogonal
array. Surface crack density is a novel parameter studied in the investigation. While
influence of each process parameters on responses is illustrated by means of percentage
contribution. Peak current is noted to show highest influence of MRR, SR, & ROC
while surface crack density is affected by pulse -on-duration.
xxxix
 Muthukumar et al. [22] investigated the effect of various process parameters
on radial overcut during machining Inconel 800 through EDM. Central composite
design is used to plan the experiments and response surface methodology is employed
to predict radial overcut obtained during use of copper electrode. Through ANOVA
analysis current and voltage are observed as the most significant parameters affecting
radial overcut.

2.3. SUMMARY

Literature survey carried-out on various domains namely non-conventional

EDM machining techniques along with various electrodes used, Ni-Cr based alloys and
soft computing techniques like Artificial neural networks (ANN), Genetic Algorithm
(GA), Regression etc. is made in the current chapter. The scrutinized report shows

1. Die sinking EDM is sporadically investigated by researchers especially in

understanding its machining behaviour on Ni-Cr based alloys.
2. Among Ni-Cr based alloys, Nimonic-901 super alloy is noted to possess
phenomenal applicability in outer space applications, and however nominal
studies are carried out in this domain.
3. Copper electrode extensively used by researchers and graphite is scarcely used.
Therefore, a comparative study is planned in this investigation to evaluate their
respective capabilities.
4. Every novel machining process requires a contemporary prediction model and
optimization. Thus, multi regression mathematical model is to be developed for
prediction of output machining parameters in this study.

xl
 CHAPTER-3
EXPERIMENTAL INVESTIGATION

3.1 INTRODUCTION
This chapter describes various steps planned to fulfil the objective of research
work. This starts with design plan consisting of levels considered for machining of
work piece followed by equipment intended to be used, response parameters to be
studied, mechanical tests to be carried-out and finally micro structural analysis
necessary.
3.2 DESIGN PLAN
The design plan of this research is to study four machining parameters namely
Peak Current (C), Pulse on-time (Ton), Pulse off-time (Toff) and Flushing Pressure
(FP) that potentially affect the quality & cost of the product. While each parameter is
though-off to be varied for 5 levels. This results in 625 (54) machining parameters for a
full factorial design. Through literature survey, TAGUCHI technique is noted to
perform the same design by a relatively a smaller number of machining runs. Thus,
MINITAB is employed to perform design plan for 4 input variables for 5 levels each.
The TAGUCHI design related to the design plan is as shown in Table 3.1.
3.3 MATERIALS REQUIRED
Nimonic-901 nickel chromium based super alloy having chemical composition
as shown in Table 3.2 is used in the current research as work piece material. Initially a
200 mm x 150 mm flat plate is procured and is cut to the required dimensions on a
Wire cut EDM. The dimensions considered are flat plate of 30 mm x 15 mm with a
thickness of 3 mm. Fig.3.1 & Fig. 3.2 shows the work piece before and after
machining.

xli
 Table 3.1 TAGUCHI design
S.No. C Ton Toff FP
1 1 1 1 1
2 1 2 2 2
3 1 3 3 3
4 1 4 4 4
5 1 5 5 5
6 2 1 2 3
7 2 2 3 4
8 2 3 4 5
9 2 4 5 1
10 2 5 1 2
11 3 1 3 5
12 3 2 4 1
13 3 3 5 2
14 3 4 1 3
15 3 5 2 4
16 4 1 4 2
17 4 2 5 3
18 4 3 1 4
19 4 4 2 5
20 4 5 3 1
21 5 1 5 4
22 5 2 1 5
23 5 3 2 1
24 5 4 3 2
25 5 5 4 3

Table 3.2 Chemical composition (wt %) of Nimonic-901super alloy

Constituents Ni Cr Co Mo Ti Al Fe Cu C
Weight % 49.0 19.0- 19.0- 5.6- 1.9- ˂ 0.6 0.7 0.2 0.04-
21.0 21.0 6.1 2.4 max max 0.08

Fig. 3.1. Nimonic-901 Super alloy work piece before machining

xlii
 Fig. 3.2. Nimonic-901 Super alloy work piece after machining
Two different electrodes namely copper and graphite are considered for
performing machining on Die-sinking EDM that are procured from Nickunj Exmp Pvt.
Ltd., Hyderabad. The cylindrical electrodes used are 12 mm in diameter and 12 cm
long. A total of 25 electrodes each were used to perform the experiments. Positive
polarity is maintained throughout the experimental process. Fig.3.3 shows the
electrodes used for machining.
EDM dielectric fluid serves two main purposes. First, it acts as a semiconductor
between the electrode and work piece to facilitate a stable and controlled spark gap
ionization condition. Second, it also acts as a flushing agent to wash and remove the
eroded debris from the spark gap area. EDM-3 dielectric fluid is used in the study

xliii
which is a high-quality oil with low viscosity to allow for faster setting that yields
higher quality finish. It reduces smoke and odour and is designed for paper cartridge
filtration up to 150 amps. A total of 120 litres of EDM oil is filled in the EDM tank for
experimentation.

Fig.3.3 Electrodes used for machining

3.4 EXPERIMENTAL PLAN

According to TAGUCHI plan intended and literature survey on prominent
process parameters, four such input parameters namely Peak Current (C), Pulse on-time
(Ton), Pulse off-time (Toff) and Flushing Pressure (FP) are considered. Each parameter
is varied for 5 levels as indicated in Table 3.3.
Table 3.3 Levels of process parameters considered
Pulse on-time Pulse off-time Flushing Pressure
Process Current (C)
(Ton) (Toff) (FP)
parameters in Amperes
in μs in μs in kg/cm2
Level 1 4 18 12 0.2
Level 2 8 36 24 0.4
Level 3 12 54 36 0.6
Level 4 16 72 48 0.8
Level 5 20 90 64 1.0

3.5 MACHINE EMPLOYED

The Die sinking EDM machine of model CREATOR CR-6C is used for
experimentation as shown in Fig. 3.4 (a, b). The specifications of the machine are given
in Table 3.4.

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3.5.1 Measurement of surface roughness
Surface of a material comprises peaks and valleys and the difference is termed
as surface roughness. Higher the difference in peaks and valleys, higher the surface
roughness. In the current study surface finish of the machined samples are noted by
using Mitutoyo SJ-210 with an accuracy of 2 μm as shown in Fig 3.5.
Table 3.4 CREATOR CR-6C

ITEM UNIT CNC

Work table dimensions (L*W) mm 650×400
Work tank inner dimensions
mm 1066×560×424
(W*D*H)
Max. capacity of dielectric fluid Litre 400
Max. electrode weight Kg 75
Max. Work piece weight Kg 1000
1210×1300×215
Machine unit dimensions (W*D*H) mm
0
Machine unit weight Kg 1950
220.346
Input voltage 3ΦV
380.415
Input power KVA 7
Working voltage (No load) V 100
High voltage V 140 or 250
Min. On-time & Min. Off-time μs 1
mm3/
Max. cutting speed 480
min
Best surface finish μmRa. 0.2
Min. electrode wear rate % 0.3

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 Control Unit

Pressure Gauge Working Tank

Die Electric Reservoir

Fig. 3.4 (a) EDM machine of model CREATOR CR-6C

Electrode

Die electric fluid

Electrode Holder

Fixture

Work Piece

Fig. 3.4 (b) EDM with different fixtures

Fig. 3.5 Surface Roughness Tester

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3.5.2 Measurement of MRR & TWR
Scientech Se-391 Electronic Balance (Fig. 3.6) with an accuracy of 0.0001g is
used to weigh the work piece and electrode before and after machining to determine the
Material removal and Tool wear rates.

Fig. 3.6 Scientech Se-391 Electronic Balance

3.5.3 Measurement of ROC
Complex shapes of tools, work pieces, components etc. are difficult to measure
theoretically. Therefore, a Coordinate Measuring Machine (CMM) Cimtrix CV 3020
(Fig. 3.7) is employed to measure the complex shape of the machined surface using a
series of points over its contour and are compared to the tool dimensions. This
difference in dimension of tool and machined contour is termed as Radial Overcut.

Fig. 3.7 Cimtrix CV 3020 Coordinate Measuring Machine

3.5 EXPERIMENT DATA ACQUIRED
Experimental data acquired from different machines employed are tabulated in
chronological order as shown in Table 3.5 and Table 3.6.

xlvii
 Table 3.5 Experimental data acquired when Copper electrode is used
S.No. C Ton Toff FP MRR SR TWR
1 4 18 12 0.2 0.82 3.458 0.003
2 8 36 12 0.4 3.655 5.756 0.086
3 12 54 12 0.6 9.525 7.324 0.125
4 16 72 12 0.8 14.629 8.456 0.257
5 20 90 12 1 19.965 9.012 0.345
6 12 36 24 0.2 5.485 5.365 0.156
7 16 54 24 0.4 11.416 8.236 0.189
8 20 72 24 0.6 17.464 9.352 0.269
9 4 90 24 0.8 1.585 5.263 0.095
10 8 18 24 1 1.146 4.653 0.056
11 20 54 36 0.2 11.979 6.152 0.181
12 4 72 36 0.4 0.993 5.695 0.076
13 8 90 36 0.6 3.81 7.569 0.198
14 12 18 36 0.8 1.402 5.123 0.145
15 16 36 36 1 4.829 5.964 0.098
16 8 72 48 0.2 2.712 5.012 0.045
17 12 90 48 0.4 6.616 7.865 0.135
18 16 18 48 0.6 1.995 4.563 0.092
19 20 36 48 0.8 5.523 6.352 0.182
20 4 54 48 1 0.728 4.152 0.096
21 16 90 64 0.2 8.916 7.689 0.235
22 20 18 64 0.4 2.391 5.246 0.089
23 4 36 64 0.6 0.442 3.658 0.008
24 8 54 64 0.8 1.745 5.365 0.059
25 12 72 64 1 3.288 6.865 0.065

Table 3.6 Experimental data acquired when Graphite electrode is used

S.No. C Ton Toff FP MRR SR TWR
1 4 18 12 0.2 1.112 1.725 1.212
2 8 36 12 0.4 5.118 2.102 3.125
3 12 54 12 0.6 11.615 2.898 9.146
4 16 72 12 0.8 17.424 3.978 10.568
5 20 90 12 1 24.316 3.985 12.898
6 12 36 24 0.2 10.123 2.247 4.264
7 16 54 24 0.4 15.798 2.965 10.356
8 20 72 24 0.6 23.138 3.597 12.365
9 4 90 24 0.8 1.271 3.546 0.987
10 8 18 24 1 2.967 1.688 1.031
11 20 54 36 0.2 17.563 3.496 11.698
12 4 72 36 0.4 1.154 2.492 0.489
13 8 90 36 0.6 4.712 3.234 3.968
14 12 18 36 0.8 4.567 2.201 4.569
15 16 36 36 1 13.615 2.552 9.326
16 8 72 48 0.2 4.501 3.201 3.536
17 12 90 48 0.4 10.401 3.246 5.362
18 16 18 48 0.6 6.273 1.992 7.365
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 19 20 36 48 0.8 14.7802 2.325 10.369
20 4 54 48 1 1.151 2.658 0.12
21 16 90 64 0.2 14.014 2.983 6.986
22 20 18 64 0.4 6.047 2.103 10.231
23 4 36 64 0.6 0.932 2.236 0.114
24 8 54 64 0.8 2.765 2.578 2.021
25 12 72 64 1 8.173 3.184 4.896

CHAPTER-4
METHODOLOGY

4.1 INTRODUCTION
Mathematical tools like regression analysis and soft computing tools like neural
network analysis are known for their potential predicting capabilities. Use of these
analyses would reduce the machining cost by minimizing R&D component of the
product cost. This is performed by many researchers using mathematical models like
regression. In recent times, neural networks, a tool of artificial intelligence has
transformed the world in all fields of science. Use of neural networks to predict
response parameters require identification of optimal architecture; which include
selection of algorithm, layers, number of neurons etc. Architecture of neural network
varies with type of application and data. In real time machining, we need to satisfy
several objectives simultaneously. Therefore, there is a need for Multi- objective
optimization.

4.2 REGRESSION
Multiple regression is an extended version of simple linear regression. This can
be used for predicting the value of a variable based on two or more constrain variable.
The variable we want to predict is called the dependent variable. The variables we are
using to predict the value of the dependent variable is called the independent variables.

xlix
 Fig. 4.1 Minitab window with loaded machining data
Multiple regression also allows you to determine the overall fit (variance
explained) of the model and the relative contribution of each of the predictors to the
total variance explained. Fig. 4.1-4.3 depicts the loading of input data, selection of
regression analysis and generation of equations using MINITAB.

Fig. 4.2 Window showing selection of regression

l
 Fig. 4.3 Result of multiple regression performed
4.3 ANALYSIS OF VARIANCE (ANOVA)

ANOVA is a statistical technique that analyses observed variance and breaks it

down into components which are the sources of variance. The test is generally used to
determine if two or more means are equal. ANOVA performs analysis on the variance
of two or more data sets to determine if the data sets have the same means. The test
calculates whether the means are within a certain percent chance of being the same
based upon the actual and expected levels of variance within each data set. F-test is
also used in the context of ANOVA for judging the significance of more than two
sample means at one and the same time. One-way analysis of variance (ANOVA) tests
determine if one given factor has a significant effect across any of the groups under
study.

li
 Fig. 4.4 ANOVA being performed on machining data

Fig. 4.5 Selection of S-N ratio criterion

A significant p-value resulting from a one-way ANOVA test would indicate that
a factor is differentially expressed in at least one of the groups analysed. If there are
more than two groups being analysed, however, the one-way ANOVA does not
specifically indicate which pair of groups exhibits statistical differences. In a two or
more-way ANOVA, the interaction between two independent variables affecting a
dependent variable can as well be studied for better decisions.

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4.4 TAGUCHI TECHNIQUE

The Taguchi method was developed by Genichi Taguchi. He developed a

method for designing experiments to investigate how different parameters affect the
mean and variance of a process performance characteristic that defines how well the
process is functioning. The experimental design proposed by Taguchi involves using
orthogonal arrays to organize the parameters affecting the process and the levels at
which they should be varied. Instead of having to test all possible combinations like the
factorial design, the Taguchi method tests pairs of combinations. This allows for the
collection of the necessary data to determine which factors most affect the product
quality with a minimum amount of experimentation, thus saving time and resources.

5. RESULTS & DISCUSSIONS

5.1. INTRODUCTION
Aeronautics is a domain witnessing extreme environmental conditions
necessitating the use of superior materials like super alloys. Nimonic 901 (Ni-Cr based)
super alloy is one such material possessing high strength at elevated temperatures along
with good wear and chemical resistances. As super alloys are difficult-to-cut materials,
non-conventional machining processes like EDM are employed where material erosion
assists in transforming a bulk into finished product. In addition, EDM also assists in
precise machining of work piece material.
5.2. PERFORMANCE EVALUATION OF COPPER ELECTRODE
Achieving superior surface finish with minimum machining time is the criterion
used in all sorts of machining operations either conventional or non-conventional.
However, always there is a trade-off between MRR and Surface Roughness of
machined sample. In addition, lower Tool Wear Rate is the desired solution to attain
economic and precise machining of finished product. The following discussion

liii
explicitly illustrates the influence of input parameters on each output response during
machining of Nimonic 901 super alloy.
5.2.1 Material Removal Rate
In EDM process a small spark gap is maintained between the electrode and the
work piece so that the applied voltage is enough to ionize the dielectric fluid resulting
in material erosion mechanism. Fig. 5.1 (a) shows that, among various process
parameters, Current is the most prominent factor followed by Pulse on-time, while
Pulse off-time has marginal affect on MRR. This phenomenon is strengthened by
ANOVA results in Table 5.1 illustrating a contribution of 49.42% by Current followed
by Pulse on-time 22.16% on MRR. However, Fig. 5.1 (b) illustrates various
phenomenon considered for MRR response variable; MRR uses “Larger is better”
characteristic. It also signifies the optimal conditions for the design in the point of
MRR parameter as C-20, Ton-90, Toff-12 and FP-0.2.

Main Effects Plot (data means) for Means

C Ton

10.0

7.5

5.0
Mean of Means

2.5

0.0
4 8 12 16 20 18 36 54 72 90
Toff FP

10.0

7.5

5.0

2.5

0.0
12 24 36 48 64 0.2 0.4 0.6 0.8 1.0

Fig. 5.1 (a) Main Effects Plot for MRR

liv
 Main Effects Plot (data means) for SN ratios
C Ton
20

15
10

Mean of SN ratios 5

4 8 12 16 20 18 36 54 72 90
Toff FP
20

15

10

12 24 36 48 64 0.2 0.4 0.6 0.8 1.0

Signal-to-noise: Larger is better

Fig. 5.1 (b) Signal to Noise ratio plot for MRR

Table 5.1. ANOVA Contribution of MRR

Source DF Seq SS % Contribution Adj SS Adj MS F-Value P-Value
C 4 364.531 49.42 364.531 91.133 15.69 0.001
Ton 4 163.496 22.16 163.496 40.874 7.04 0.010
Toff 4 152.737 20.71 152.737 38.184 6.58 0.012
FP 4 10.279 1.3 10.279 2.570 0.44 0.775
Error 8 46.456 6.29 46.456 5.807
Total 24 737.499 100

5.2.2. Surface Roughness

Generally an EDM machined surface consists of craters, globules, pockmarks,
voids, pores, cracks and uneven fusing structures, which create unevenness of the
surface area which is termed as Surface Roughness. Surface Roughness is directly
proportional to Current and Pulse on-time as evident in the main effects plot diagram of
SR as shown in Fig. 5.2 (a). This phenomenon is strengthened by ANOVA results in
Table 5.2 illustrating a contribution of 42.54% by Pulse on-time 39.18% followed by
Current on SR. However, Fig. 5.1 (b) illustrates various phenomenon considered for SR
response variable; SR uses “Smaller is better” characteristic. It also signifies the
optimal conditions for the design in the point of SR parameter as C-20, Ton-90, Toff-
12 and FP-0.4.
Table 5.2. ANOVA Contribution of SR
Source DF Seq SS % Contribution Adj SS Adj MS F-Value P-Value
C 4 25.5272 39.18 25.5272 6.3818 15.74 0.001
Ton 4 27.7176 42.54 27.7176 6.9294 17.09 0.001
Toff 4 5.3417 8.19 5.3417 1.3354 3.29 0.071

lv
 FP 4 3.3209 5.09 3.3209 0.8302 2.05 0.180
Error 8 3.2444 4.97 3.2444 0.4056
Total 24 65.1518 100

Main Effects Plot (data means) for Means

C Ton

5
Mean of Means

4
4 8 12 16 20 18 36 54 72 90
Toff FP

4
12 24 36 48 64 0.2 0.4 0.6 0.8 1.0

Fig. 5.2 (a) Main Effects Plot for SR

Main Effects Plot (data means) for SN ratios

C Ton
-13
-14
-15
Mean of SN ratios

-16
-17

4 8 12 16 20 18 36 54 72 90
Toff FP
-13
-14
-15
-16
-17

12 24 36 48 64 0.2 0.4 0.6 0.8 1.0

Signal-to-noise: Smaller is better

Fig. 5.2 (b) Signal to Noise ratio plot for SR

5.2.3. Tool Wear Rate

The main effects plot of Tool Wear Rate shown in Fig. 5.3 (a) depicts a linear
variation of TWR with increase in Current and Pulse on-time but by a different factor.
An increase in Pulse off-time seems to reduce TWR while Flushing Pressure shows
negligible effect. In addition ANOVA of means for TWR as in Table 5.2 illustrates that
Current is highly influencing the TWR with a percentage contribution of 47.03%

lvi
followed by pulse on time of 25.25%. ‘Smaller the better’ is the desired characteristic
for Tool Wear Rate to control the cost of machining. Fig. 5.3 (b) signifies the optimal
conditions for the design in the point of TWR parameter as C-20, Ton-90, Toff-24 and
FP-0.8.
Table 5.3. ANOVA Contribution of TWR
Source DF Seq SS % Contribution Adj SS Adj MS F-Value P-Value
C 4 0.080610 47.03 0.080610 0.020152 6.15 0.015
Ton 4 0.043278 25.25 0.043278 0.010819 3.30 0.071
Toff 4 0.018095 10.55 0.018095 0.004524 1.38 0.323
FP 4 0.003178 1.85 0.003178 0.000794 0.24 0.906
Error 8 0.026214 15.29 0.026214 0.003277
Total 24 0.171374 100

Main Effects Plot (data means) for Means

C Ton

0.20

0.15

0.10
Mean of Means

0.05
4 8 12 16 20 18 36 54 72 90
Toff FP
0.20

0.15

0.10

0.05
12 24 36 48 64 0.2 0.4 0.6 0.8 1.0

Fig. 5.3 (a) Main Effects Plot for TWR

Main Effects Plot (data means) for SN ratios

C Ton
30

25

20
Mean of SN ratios

15
4 8 12 16 20 18 36 54 72 90
Toff FP
30

25

20

15
12 24 36 48 64 0.2 0.4 0.6 0.8 1.0
Signal-to-noise: Smaller is better

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 Fig. 5.3 (b) Signal to Noise ratio plot for TWR

Validation runs are performed for the optimal conditions as many of the
optimum conditions lie outside the L25 orthogonal array and are listed in Table 5.4 for
comparison with predicted optimum response values. The predicted values for optimal
conditions are attained from Eq.5.1–5.3 (MRR, SR and TWR respectively) obtained
from multiple regression analysis conducted for experimental values. The average error
obtained between the predicted and experimental runs is 4.58% i.e. the accuracy of the
developed models is as high as 95.42%.

 Regression Analysis: MRR versus C, Ton, Toff, FP

The regression equation is

MRR = - 2.78 + 0.671 C + 0.0950 Ton - 0.127 Toff - 0.00 FP ----------(Equ.
5.1)

 Regression Analysis: SR versus C, Ton, Toff, FP

The regression equation is

SR = 2.52 + 0.172 C + 0.0411 Ton - 0.0233 Toff + 0.370 FP----------(Equ. 5.2)

 Regression Analysis: TWR versus C, Ton, Toff, FP

The regression equation is

TWR = - 0.0352 + 0.0100 C + 0.00159 Ton - 0.00146 Toff + 0.0243 FP-----
(Equ. 5.3)

Table 5.4 Validation of Performance Results

Parameter Optimum Condition

Current- 20
Pulse on-time- 90
MRR
Pulse off-time- 12
Flushing Pressure- 0.2
Current- 20
Pulse on-time- 90
SR
Pulse off-time- 12
Flushing Pressure- 0.4
Current- 20
Pulse on-time- 90
TWR
Pulse off-time- 24
Flushing Pressure- 0.8

5.2.4. SUMMARY

lviii
 The present study exploits the influence of various Die sinking EDM process
parameters on machinability of Nimonic-901 super alloy by Taguchi technique. At
optimal condition an increase in MRR is noted, with an increase of Current & Pulse on-
time and decreasing Pulse off-time & Flushing Pressure. The TWR at optimal condition
increases, with an increase of Current & Pulse on-time while, a contrary result is seen
for Pulse off-time. Flushing Pressure has negligible significance on TWR.
Increase in Current and Pulse on-time, increases the Surface Roughness at
optimal condition. While, increase in Pulse off-time leads to decrease in Surface
Roughness. Flushing pressure is observed to nominally affect the Surface Roughness.
All responses are greatly influenced by Current while Surface Roughness is
significantly influenced by Current and Pulse on-time. Flushing Pressure followed by
Pulse off-time has nominal influence on output responses. Validation runs performed
for optimal conditions showed improvement in different output responses compared to
initial experimentation.

5.3. PERFORMANCE EVALUATION OF GRAPHITE ELECTRODE

5.3.1 Material Removal Rate
In EDM process material erosion occurs due to local melting that is later
flushed out by the dielectric fluid. It is impossible for dielectric fluid to flush out all the
waste material which results in formation of re-cast or white layer that affects material
characteristics. Fig.5.4 (a) shows that, among various process parameters, Current is the
most prominent factor followed by Pulse on-time, while Pulse off-time has marginal
effect on MRR. This phenomenon is strengthening by ANOVA results in Table 5.5
illustrating a contribution of 72.74% by Current followed by Pulse on-time 13.02%, on
MRR. Various researchers’ investigation on different Ni-Cr alloy revealed that Current
and Pulse on-time have nearly equal effect on MRR however; a marginal variation is
noted for Ton in our investigation. This distinction is achieved by the graphite electrode
material rather than copper in their research. Fig. 5.1 (b) illustrates various
phenomenon considered for MRR response variable; MRR uses “Larger is better”
characteristic. It also signifies the optimal conditions for the design in the point of
MRR parameter as C-20, Ton-90, Toff-12 and FP-0.2.

lix
 Main Effects Plot (data means) for Means
C Ton
16

12

Mean of Means
4

0
4 8 12 16 20 18 36 54 72 90
Toff FP
16

12

0
12 24 36 48 64 0.2 0.4 0.6 0.8 1.0

Fig. 5.4 (a) Main Effects Plot for MRR

Main Effects Plot (data means) for SN ratios

C Ton
24

18

12
Mean of SN ratios

0
4 8 12 16 20 18 36 54 72 90
Toff FP
24

18

12

0
12 24 36 48 64 0.2 0.4 0.6 0.8 1.0
Signal-to-noise: Larger is better

Fig. 5.4 (b) Signal to Noise ratio plot for MRR

Table 5.5. ANOVA Contribution of MRR

Source DF Seq SS % Contribution Adj SS Adj MS F-Value P-Value
C 4 865.988 72.74 865.988 216.497 38.14 0.000
Ton 4 155.014 13.02 155.014 38.753 6.83 0.011
Toff 4 105.145 8.83 105.145 26.286 4.63 0.031
FP 4 18.914 1.58 18.914 4.729 0.83 0.540
Error 8 45.407 3.81 45.407 5.676
Total 24 1190.469 100

5.3.2. Surface Roughness

The variations in surface topography of a material lead to various unpredictable
metallurgical anomalies during application. Therefore, Surface Roughness is a most
desired factor during machining. From the plots of Fig.5.5 (a) depicting the main

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effects of Surface Roughness, Current and Pulse on-time are noted to have identical
and linear degree of variation. A contrary nature is observed for Pulse off-time.
Variation in Flushing Pressure seems to possess negligible change in Surface
Roughness.
The analysis of variance details of our investigation (Table 5.6) elucidates that
Pulse on-time is most influencing parameter followed by Current and Pulse off-time.
This illustrates that; higher the Pulse frequency (Ton) higher will be the rate of material
splash getting solidified by dielectric fluid resulting in a bad surface topography. The
percentage contribution of Pulse on-time is 75.15% on Surface Roughness. Fig. 5.5 (b)
illustrates various phenomenon considered for SR response variable; SR uses “Smaller
is better” characteristic. It also signifies the optimal conditions for the design in the
point of SR parameter as C-20, Ton-90, Toff-12 and FP-0.8.
Table 5.6. ANOVA Contribution of SR
Source DF Seq SS % Contribution Adj SS Adj MS F-Value P-Value
C 4 1.1303 10.60 1.1303 0.2826 2.52 0.124
Ton 4 8.0121 75.15 8.0121 2.0030 17.89 0.000
Toff 4 0.3050 2.86 0.3050 0.0762 0.68 0.625
FP 4 0.3180 2.98 0.3180 0.0795 0.71 0.608
Error 8 0.8959 8.40 0.8959 0.1120
Total 24 10.6613 100

Main Effects Plot (data means) for Means

C Ton
3.6

3.2

2.8

2.4
Mean of Means

2.0
4 8 12 16 20 18 36 54 72 90
Toff FP
3.6

3.2

2.8

2.4

2.0
12 24 36 48 64 0.2 0.4 0.6 0.8 1.0

Fig. 5.5 (a) Main Effects Plot for SR

lxi
 Main Effects Plot (data means) for SN ratios
C Ton
-6
-7
-8
-9
Mean of SN ratios -10

4 8 12 16 20 18 36 54 72 90
Toff FP
-6
-7
-8
-9
-10

12 24 36 48 64 0.2 0.4 0.6 0.8 1.0

Signal-to-noise: Smaller is better

Fig. 5.5 (b) Signal to Noise ratio plot for SR

5.3.3. Tool Wear Rate

‘Smaller the better’ is the desired characteristic for Tool Wear Rate to control
the cost of machining. The main effects plot of Tool Wear Rate shown in Fig.5.6 (a)
depicts, a linear variation of TWR with increase in Current and Pulse on-time but by a
different factor. Pulse off-time and flushing pressure show a negligible effect on TWR.
In addition, ANOVA of means for TWR as in Table 5.7 illustrates that Current is
highly influencing the TWR as indicated by percentage contribution of 90.91%,
compared to other process parameters. A similar trend of increase in TWR with an
increase in Current is noted by investigators in many articles. Moreover, none of the
investigations used graphite electrode however, none of them used Nimonic super
alloy. ‘Smaller the better’ is the desired characteristic for Tool Wear Rate to control
the cost of machining. Fig. 5.6 (b) signifies the optimal conditions for the design in the
point of TWR parameter as C-20, Ton-90, Toff-12 and FP-0.2.
Table 5.7. ANOVA Contribution of TWR
Source DF Seq SS % Contribution Adj SS Adj MS F-Value P-Value
C 4 394.727 90.91 394.727 98.682 108.49 0.000
Ton 4 10.393 2.39 10.393 2.598 2.86 0.096
Toff 4 18.225 4.19 18.225 4.556 5.01 0.026
FP 4 3.530 0.81 3.530 0.882 0.97 0.474
Error 8 7.277 1.67 7.277 0.910
Total 24 434.152 100

lxii
 Main Effects Plot (data means) for Means
C Ton

10.0

7.5

5.0
Mean of Means
2.5

0.0
4 8 12 16 20 18 36 54 72 90
Toff FP

10.0

7.5

5.0

2.5

0.0
12 24 36 48 64 0.2 0.4 0.6 0.8 1.0

Fig. 5.6 (a) Main Effects Plot for TWR

Main Effects Plot (data means) for SN ratios

C Ton
10

-10
Mean of SN ratios

-20
4 8 12 16 20 18 36 54 72 90
Toff FP
10

-10

-20
12 24 36 48 64 0.2 0.4 0.6 0.8 1.0
Signal-to-noise: Smaller is better

Fig. 5.6 (b) Signal to Noise ratio plot for TWR

The optimum conditions for various responses are observed to lie outside the
L25 orthogonal array which necessitates the need for validation experiments.
Therefore, validation runs are performed for the optimal conditions and are listed in
Table 5.8 for comparison with predicted optimum response values. The predicted
values for optimal conditions are attained from Eq.5.4-5.6 (MRR, SR and TWR
respectively) obtained from regression analysis conducted for experimental values.
The average error obtained between the predicted and experimental runs is 5.07% i.e.
the accuracy of the developed models is as high as 94.93%.

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  Regression Analysis: MRR versus C, Ton, Toff, FP

The regression equation is

MRR = - 4.57 + 1.04 C + 0.0859 Ton - 0.111 Toff + 0.81 FP ----------(Equ.
5.4)

 Regression Analysis: SR versus C, Ton, Toff, FP

The regression equation is

SR = 1.22 + 0.0368 C + 0.0217 Ton - 0.00596 Toff + 0.255 FP ----------(Equ.
5.5)

 Regression Analysis: TWR versus C, Ton, Toff, FP

The regression equation is

TWR = - 1.94 + 0.701 C + 0.0180 Ton - 0.0429 Toff + 0.010 FP ----------(Equ.
5.6)

Table 5.8 Validation of Performance Results

Parameter Optimum Condition

Current- 20
Pulse on-time- 90
MRR
Pulse off-time- 12
Flushing Pressure- 0.2
Current- 20
Pulse on-time- 90
SR
Pulse off-time- 12
Flushing Pressure- 0.8
Current- 20
Pulse on-time- 90
TWR
Pulse off-time- 12
Flushing Pressure- 0.2

5.3.4. SUMMARY
The present study exploits the influence of various Die sinking EDM process
parameters on machinability of Nimonic-901 super alloy by Taguchi technique. The
following attributes are summarized
 At optimal condition, MRR increases with increase of Current & Pulse
on-time, while MRR is noted to be inversely proportional to Pulse off-
time. As Flushing Pressure increases MRR decreases up to 0.4 Flushing
Pressure and then increases.

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  The TWR at optimal condition increases with increase of Current &
Pulse on-time. While, a contrary result is seen for Pulse off-time.
Flushing pressure has negligible significance on TWR.
 Increase in Current and Pulse on-time, increases the Surface Roughness
at optimal condition. While, increase in Pulse off-time leads to decrease
in Surface Roughness. Flushing pressure is observed to nominally affect
the Surface Roughness.
 All responses are greatly influenced by Current while Surface
Roughness is significantly influenced by Pulse on-time followed by
Current.
 Flushing pressure followed by Pulse off-time has nominal influence on
output responses.
 Validation Experiments performed for optimal conditions showed
improvement in different output responses compared to initial
experimentation run.

5.4. COMPARATIVE ANALYSIS

5.4.1. Introduction
Quality of a product is largely victimized by product characteristics like Surface
Roughness. However, these characteristics tend to change with machining parameters,
type of components and machining environment. Earlier topics of this chapter dealt
with, machining parameters affecting the product quality and machining cost i.e. using
copper electrode in Sec.5.2 and graphite electrode in Sec.5.3. As comparative studies
related to use of electrode is not identified from our literature survey, influence of
electrode on machining characteristics is elucidated in detail in the current section.
Here the dominance of each electrode in correlation to specific response parameter
without much discussion associated with literature that is already made in the earlier
topics.
5.4.2. Material Removal Rate
“Larger the better” is the necessary characteristic for MRR. This characteristic
of MRR seems to be satisfied by Peak Current used during machining, especially while
using graphite electrode than copper. The same can also be illustrated through %
contributions of 72.74 vs 49.42. Pulse on-time is the next consecutive parameter to
Current affecting MRR. However, the contribution showed that copper electrode

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produces higher MRR compared to graphite i.e. 22.16% and 13.02% respectively.
Pulse off-time seems to inversely affect MRR i.e. low Pulse off-time possesses higher
MRR. Thus, copper electrode with a relatively lower Pulse off-time satisfies the
necessary characteristic of MRR.
Flushing pressure illustrated negligible effect on MRR irrespective of type of
electrode used. Among the electrodes, graphite electrode has no influence on MRR in
the context of Flushing Pressure. This phenomenon may be due to adhering of flushed
material to graphite electrode as illustrated by various researchers.
5.4.3. Surface Roughness
Super finishing surface is always the most desirable characteristic of a product.
This makes the product ergonomically variable and leads to minimal surface
imperfection, thus enhancing the mechanical capabilities of the product. During the use
of copper electrode, Pulse on-time is noted to greatly affect Surface Roughness
succeeded by Current. The contribution of Pulse on-time is 42.54% compared to
39.18% of Current. The other parameters like Pulse off-time & Flushing Pressure has
negligible effect on Surface Roughness.
Use of graphite electrode showed contrary results with minimal significance of
Current on surface finish. In this case Pulse on-time is noted to affect Surface
Roughness more potentially than any other parameter. As “smaller the better” is the
characteristic for SR minimum Pulse on-time along with graphite electrode will possess
good surface finish leading to elimination of secondary machining in certain products.
5.4.4. Tool Wear Rate
“Smaller the better” is the characteristic required for TWR. Current is noted as
the most significant factor increasing TWR irrespective of type of electrode. Especially,
higher Current damage the graphite electrode than copper as the % contribution is
90.91 vs. 47.03 for copper. Pulse on-time increases the TWR during usage of copper
electrode while negligible effect is noted for graphite electrode. This also resembles in
% contribution of 25.25 for copper to 2.39 for graphite. Though Pulse off-time has an
inverse effect on TWR, use of graphite possessed intangibly small electrode wear.
While, Flushing Pressure has no effect on TWR irrespective of type of
electrode. As minimal tool wear is the necessary condition for optimal machining,
graphite electrode used with low Current & Pulse on-time and higher Pulse off-time
would be the effective solution.

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 CHAPTER-6
CONCLUSIONS & FUTURE SCOPE
6.1 INTRODUCTION
In the present investigation a detailed emphasis is made in correlating the
effect of various output responses with input variables considered for machining
Nimonic-901, a Ni-Cr based super alloy performed on a Die-sinking EDM. The output
responses studied are Material Removal Rate (MRR), Surface Roughness (SR) and
Tool Wear Rate (TWR), while the input variables employed in the study include some
influential regular parameters like Peak Current (C), Pulse on-time (Ton), Pulse off-
time (Toff) in combination with scarcely used parameter named Flushing Pressure
(FP).
The entire study envisages the various ways of reducing the product cost
without sacrificing the quality. Among the output responses considered in the study,
MRR and TWR affect the machining cost of the product through “higher the best” and
“lower the best” strategies as respective necessary conditions. Research biased towards
minimizing machining cost possesses contrary effect on product quality. Hence
response parameters like Surface Roughness is also included for analysis that takes care
of product quality following “lower the better” phenomenon.
Numerous analyses are planned on machinability of Ni-Cr alloy considering
five levels for each input parameter resulting in 625 machining sequences, moreover as
two different electrodes namely copper and graphite are employed in the study, the total

lxvii
sequences should be 1250. However, among all the full factorial sequences planned
some sequences show nominal effect on responses, so in order to filter such sequences
from the investigation L25 orthogonal array is employed for copper and graphite
electrodes.
The study of machining characteristics is performed by ANOVA analysis where
contribution of each input on each output response is studied to understand the most
influential input parameter. In addition, following the necessary conditions of output
responses, optimal process sequence is identified. A comparative study between the
different electrodes is performed to identify the better electrode, taking into
consideration various aspects of product i.e. output responses. In addition Regression
analysis has been carried out to estimate the responses.
6.2 MACHINING CAPABILITIES
6.2.1 Response Parameters
The hierarchy of machining parameters affecting each response is detailed
individually in the following steps
 MRR increases with increase of Current & Pulse on-time, while
inversely proportional to Pulse off-time. As Flushing Pressure increases
MRR decreases up to 0.4 Flushing Pressure and then increases.
 The TWR increases with an increase of Current & Pulse on-time. While,
a contrary result is seen for Pulse off-time. Flushing Pressure has
negligible significance on TWR.
 Increasing the Current and Pulse on-time, increases the Surface
Roughness (SR). While, increase in Pulse off-time leads to decrease in
Surface Roughness. Flushing Pressure is observed to nominally affect
the Surface Roughness.
In general, a precise note of effect of machining parameters on responses is as
follows
 All responses are greatly influenced by Current while Surface Roughness is
significantly influenced by Pulse on-time followed by Current.
 Flushing Pressure followed by Pulse off-time has nominal influence on
output responses.
 Validation Experiments performed for optimal conditions showed
improvement in different output responses compared to initial
experimentation run.

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6.2.2 Type of Electrode
If the response variables are individually the necessary conditions during
machining; graphite electrode is noted to possess superior surface finish, good
precision machining and high MRR while copper is only capable of machining
Nimonic with less TWR.
When a combination of response variables is to be achieved, higher Peak
Currents used with copper electrode satisfies all the responses. However, higher Pulse
on-time considered using graphite electrode satisfies the MRR and TWR with an
exception of surface finish.
6.3 PREDICTION CAPABILITIES
It is to be noted that phenomenal prediction accuracy of 93.55% has been found
using regression analysis, when copper electrode is used during EDM machining.
Moreover, prediction accuracy of 95.53% using regression analysis for graphite
electrode.

6. 6 FUTURE SCOPE
 Machining Characteristics of Nimonic-901 Super alloy can be studied by using
other unconventional machining process like water jet machining, laser beam
machining etc.
 Various output responses like white layer thickness, surface crack density can
be studied.
 Various prediction tools like ANN, RSM, fuzzy, genetic programming can be
adopted.
 Different Multi-objective optimization techniques like PSO, Differential
Evolution Algorithm etc., can be adopted.

CHAPTER-7
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