The current issue and full text archive of this journal is available on Emerald Insight at:

https://www.emerald.com/insight/1573-6105.htm

Wire EDM cutting of Inconel 718 Wire EDM

cutting of
nickel-based superalloy: Inconel 718

kerf and MRR analysis

Meltem Altin Karataş 653
Department of Machinery and Metal Technology, Gerede Vocational School,
Bolu Abant Izzet Baysal University, Bolu, Turkey Received 5 May 2022
Revised 16 June 2022
Accepted 20 June 2022
Abstract
Purpose – Inconel 718 (IN718) is a high-performance nickel-based superalloy with high oxidation-corrosion-
temperature resistance, high strength (tensile, fatigue, creep and rupture), durability, toughness, hardness and
dimensional stability, which is difficult to machine with traditional fabrication methods. To overcome these
difficulties, wire electrical discharge machining (WEDM), one of the modern manufacturing methods, is used.
Design/methodology/approach – Main performance criteria in WEDM; material removal rate (MRR),
cutting speed, surface roughness, cutting width (kerf) and wire wear rate. In this study, the effect of processing
parameters on kerf and MRR because of processing IN718 in WEDM was investigated. Machining parameters,
voltage, wire feed rate and dielectric fluid pressure were determined. Deionized water was used as a dielectric
fluid and 0.3 mm brass wire was used as wire in the experiments. Gray Relational Analysis (GRA), which is one
of the multi-criteria decision-making methods, has been applied for the optimization of the machining
parameters in the cutting process with the WEDM. Analysis of variance (ANOVA) was used to determine the
effect percentages of the cut-off parameters.
Findings – The parameter with the highest effect was determined as tension with a rate of 76.95% for kerf and
91.21% for MRR.
Originality/value – The novel approach uses Taguchi-based GRA optimization as a result of cutting IN718
with WEDM, reducing cost and time consumption.
Keywords Inconel 718, Wire electrical discharge machining, Material removal rate, Kerf, Taguchi-based gray
relational analysis
Paper type Research paper

1. Introduction
Nickel-based materials are commonly used in the aerospace, medical, nuclear and chemical
industries thanks to their exceptional resistance to creep, corrosion and thermal fatigue at
high-level temperatures (Wang et al., 2013; Varol Ozkavak et al., 2021). Nickel alloys are
preferred for use in turbine sections of jet engines, as they perfectly preserve their mechanical
and chemical properties even after exposure to extremely high temperatures (Ulutan and
Ozel, 2011). For example, 50% of the weight of a jet engine is Inconel 718 (IN718). IN718 – it is
in the “hard to machine” material group due to its toughness, deformation-hardening
tendency and resistance to shearing caused by shear stress (Varol Ozkavak et al., 2021). It is
known that non-traditional manufacturing methods are often used for cutting such difficult-
to-machine materials. Sometimes, non-traditional machining methods can be used as a
finishing process, as a continuation of another machining method, with the advantage of
getting good surface roughness (Bertolini et al., 2019).
Wire electrical discharge machining (WEDM) is an unconventional machining process
that abrades the workpiece by spark initiation of a pulsed voltage discrepancy between a wire
electrode and a conductive workpiece (Figure 1) (Kuş and Motorcu, 2017). In the principle of
cutting by WEDM, the materials are processed with the electric discharge (spark) between Multidiscipline Modeling in
Materials and Structures
Vol. 18 No. 4, 2022
pp. 653-672
€ urk Kalıp A.Ş. who contributed to the realization of the
The author would like to thank Yeni Ozt€ © Emerald Publishing Limited
1573-6105
experiments. DOI 10.1108/MMMS-05-2022-0080
MMMS
18,4

654

Figure 1.
Schematic view of
WEDM process

the moving wire electrode and the workpiece. The heat of each spark erodes a small part of the
material (by melting and vaporizing the workpiece) while some of the wire material is eroded
(Vani et al., 2018). The deionized liquid is used both to remove these particles from the cut and
to prevent heat generation in the workpiece. If the cooling process is not applied, the thermal
expansion of the workpiece will affect its size and accuracy. Such removal of material, high
strength, hardness, toughness, etc. of the workpiece material is advantageous when it is
difficult to machine with conventional machine tools for reasons (Newton et al., 2009). The
biggest challenge in WEDM is to meet the requirements for surface integrity (Welling, 2014).
WEDM is an alternative machining method for producing complex Inconel part geometries
(Li et al., 2013).
Although the main WEDM performance measurements are defined as material removal
rate (MRR), cutting speed, average surface roughness (Ra), cutting width (kerf) and wire wear
rate; different types of surface integrity parameters such as white layer thickness, heat
affected zone (HAZ) and surface crack density are also performance criteria of processing
with WEDM (Jahan, 2014). Because there are so many variable processing parameters in
WEDM, it is difficult to determine and use the optimum one (Tosun et al., 2004). Various
researchers have carried out many studies to improve MRR, kerf and Ra values due to their
importance in WEDM (Vani et al., 2018; Rajyalakshmi and Ramaiah, 2013; Lin and Tarng,
1998; Julong, 1989; Lin et al., 2000; Sivaprakasam et al., 2019; Dhanunjaya et al., 2018; Sheth
et al., 2021; Shandilya et al., 2020; Kumar et al., 2018a). Also; among the nickel-based alloys,
Inconel 718 is the most widely used alloy; It has also been extensively investigated in terms of
surface integrity, residual stress and machinability (Sharman et al., 2004, 2006, 2008;
Kitagawa et al., 1997; Ezugwu and Tang, 1995; Liao and Shiue, 1996; Rahman et al., 1997;
Ezugwu et al., 1999; Darwish, 2000; Li et al., 2002; Arunachalam et al., 2004a, b; Coelho et al.,
2004; Dudzinski et al., 2004; Mitrofanov et al., 2004; Pawade et al., 2007, 2008; Courbon et al.,
2009; Lorentzon et al., 2009).
Sheth et al. (2021) examined the effect of input variables such as pulse-on time, current and
pulse-off time on MRR and surface quality in WEDM of IN718 superalloy. Optimum
processing parameters were obtained with a combination of 55 ms pulse-on time, 5 ms pulse-
off time and 2 A current (Sheth et al., 2021). Sivaprakasam et al. (2019) investigated the effects
of graphite nano powder used in dielectric medium on kerf, MRR and Ra in cutting IN718
superalloy by microwire electrical discharge. As a result of their experimental study, they
determined that the presence of graphite nano powder in the dielectric significantly improved Wire EDM
the topography and roughness of the machined surface (Sivaprakasam et al., 2019). cutting of
Vani et al. (2018) researched the effects of machining parameters on kerf, MRR and Ra in
wire electrical discharge cutting of IN718 superalloy using two different wires (0.25 mm semi-
Inconel 718
hard brass wire and zinc-plated brass wire). From the experimental results, they observed that
kerf, MRR and Ra increased with increasing pulse-on time and current. They stated that the
wire feed rate significantly affects kerf, with higher pulse-off time resulting in smaller MRR and
kerf (Vani et al., 2018). Dhanunjaya et al. (2018) also examined the effects of machining 655
parameters on kerf, MRR and Ra in wire electrical discharge cutting of IN718 superalloy using
two different wires (semi-hard brass wire and zinc-plated brass wire). As a result of their
experimental study, they concluded that zinc-plated brass wire can be used for maximum MRR
and minimum Ra, and semi-rigid brass wire can be used for minimum kerf (Dhanunjaya et al.,
2018). Thejasree et al. (2021) evaluated the MRR, Ra and overcut performance properties of
IN718 superalloy by applying a single criterion optimization with the Taguchi method in wire
electrical discharge cutting. They stated that pulse-on time is the most important process
parameter for better performance characteristics. They stated that the most effective
machining parameter for MRR is pulse-on time and as the pulse-on time increases, the amount
of electrons acting on the workpiece will increase, so more material will be eroded from the
workpiece surface (Thejasree et al., 2021). Kumar and Singh (2021) examined the impact of
process parameters such as pulse-on time, open circuit tension, wire tension and wire feed rate
on MRR and Ra in WEDM of IN718 superalloy using brass wire. They found that pulse-on time
was the most influential parameter on MRR and Ra. They stated that the most suitable
processing parameter for MRR was obtained with 0.75 ms pulse-on time, 60 V open-circuit
voltage, 1,700 gr wire tension and 1 m/min wire feed speed. The most suitable processing
parameters for Ra; were obtained with 0.25 ms pulse-on time, 50 V open-circuit voltage, 1,100 gr
wire tension and 1 m/min wire feed speed (Kumar and Singh, 2021). Divya et al. (2020) obtained
1.626 mm surface roughness, 0.3234 mm kerf and 4.135 mm3/min MRR with optimum cutting
parameters on cutting Inconel, titanium and aluminum alloys using WEDM (Divya et al., 2020).
Abhilash and Chakradhar (2020a) investigated the surface integrity of the workpiece attained
by WEDM of IN718 superalloy (Abhilash and Chakradhar, 2020a). Chen et al. (2016)
characterized the surface integrity of IN718 superalloy in WEDM and investigated its effect on
fatigue performance in the four-point bending fatigue mode at room temperature (Chen et al.,
2016). Kumar et al. (2018a, b) investigated the effect of wire electrode on surface roughness and
corner error in WEDM of IN718 superalloy. The results they obtained showed that the zinc-
coated brass wire performed better than the uncoated brass wire in terms of surface roughness
and corner error (Kumar et al., 2018b). Ekici et al. (2016) investigated the effects of wire speed,
pulse-on time and pulse-off time on kerf and surface roughness properties in wire electrical
discharge processing of Al/B4C-Gr composite. As a result of their ANOVA analysis, they
concluded that the most effective parameter is pulse-on time (Ekici et al., 2016).
Taguchi experimental design method, one of the widely used optimization methods, is a
simple, effective and systematic approach to derive optimum machining parameters with
minimum experimental cost (Mahapatra and Patnaik, 2007). However, with the Taguchi
method, only one criterion optimization is performed. Optimizing multiple performance
features is more complex than optimizing a single performance feature (Natarajan and
Arunachalam, 2011). Taguchi-based Gray Relational Analysis (GRA) is a multi-criteria
optimization method used in applications where uncertainty is concerned. Gray system
theory uses gray relational generation and calculates the gray relational coefficient (Julong,
1989; Patel et al., 2010). GRA is used in various applications to determine the most suitable
parameters for different machining processes (Natarajan and Arunachalam, 2011). Multi-
criteria optimization can be converted to a single associative degree optimization, so the
Taguchi-based GRA method is widely used (Rajyalakshmi and Ramaiah, 2013).
MMMS IN718 is commonly used in high-temperature environments, high-performance aircraft
18,4 and missile weapon systems (Yang et al., 2017). This material is preferred because it preserves
its mechanical properties during processing. However, these materials are very difficult to
process using traditional manufacturing methods. At the same time, the high temperatures
that occur during the processing of such high-strength materials with traditional
manufacturing methods both affect the tool life negatively and the surface quality
obtained is low. In addition, this situation causes an increase in the processing cost. WEDM,
656 an unconventional manufacturing method that can be applied to all kinds of conductive
materials, regardless of the hardness of the material (because there is no contact between the
workpiece and the electrode) (Yang et al., 2017), offers an effective solution to overcome the
limitations of traditional manufacturing methods in the machining of ultra-hard, high-
strength, temperature-resistant materials and alloys (Garg et al., 2017).
In studies with WEDM, optimization was made by using pulse-on time and pulse-off time,
which are generally the most effective parameters (Kuş and Motorcu, 2017; Sheth et al., 2021;
Thejasree et al., 2021). Studies using voltage, wire feed rate and dielectric fluid pressure as
processing parameters are limited. Also, the single-criteria optimization method has been
used in the studies generally, and the number of studies with multi-criteria optimization is
also low. Therefore, the effect of different processing parameters (voltage, wire feed speed
and dielectric fluid pressure) was investigated, and the cutting parameters were optimized in
order to determine the optimum MRR and kerf values, which are very important in WEDM.
Taguchi-based GRA, one of the multi-criteria decision-making methods, was applied to
optimize the processing parameters. GRA and gray relational grade analysis of variance
(ANOVA) were used to determine the effect percentages of process parameters.

2. Material and methods

2.1 Experimental procedure
In this experimental study, IN718 superalloy material with dimensions of 150 3 20 3 9 mm
was used as the workpiece. The chemical composition of IN718 material is given in Table 1
and its mechanical properties are given in Table 2.
A 2008 model CNC-controlled Mitsubishi FA20 wire electrical discharge machine was
used for cutting IN718 superalloy. Machining parameters that may affect the cut or drill
quality in WEDM are outlined in the fishbone (Ishikawa) cause-effect diagram in Figure 2
(Patel et al., 2014; Singh and Bhardwaj, 2011).
Processing parameters in this experimental study; among the wire electrical discharge
machine variables, voltage (VG), dielectric fluid pressure (LQ) and wire feed rate (WS) were
determined (Table 3). The current (Ip) value (10 A) is kept constant. Deionized water was used
as dielectric fluid and 0.3 mm brass wire was used as wire in the experiments.

Table 1. Ni Cr Nb Mo Ti Al Mn Si C Cu P
Chemical composition
of IN718 superalloy 51.34 17.89 5.04 3.14 0.99 0.57 0.18 0.16 0.046 0.031 0.011
(%wt) Source(s): Donachie and Donachie (2002)

Table 2. Yield strength (MPa) Tensile strength (MPa) Elongation (%)

Some mechanical
properties of IN718 1,032 1,072 14
superalloy Source(s): Donachie and Donachie (2002)
 Wire EDM
cutting of
Inconel 718

657

Figure 2.
Fishbone (Ishikawa)
cause-effect diagram
for WEDM process

Parameters Symbol Unit Level 1 Level 2 Level 3 Table 3.

Processing parameters
Voltage gap VG V 46 56 66 and levels used for
Dielectric liquid pressure LQ kg/cm2 10 12 14 cutting IN718
Wire feed rate WS m/dak 8 10 12 superalloy

Optimization of machining parameters in Taguchi experimental design approach is made in

order to obtain high quality without increasing the cost. This method creates orthogonal
arrays from which important data can be collected with as few repetitions as possible to
design and conduct experiments. The Taguchi Method was used to define the ideal
machining parameters and to evaluate the effects of the defined machining parameters on
kerf and MRR values, and the most suitable orthogonal array L9 (33) was chosen (Table 4).
In the Taguchi method, there are quality characteristics such as “nominal is best”, “smaller
is better” and “larger is better”. In this study, the minimum value was taken for the lowest kerf
value and “smaller is better” was chosen to calculate the optimal S/N ratio for better product
quality and lowest cost (Equation 1). For the MRR, the “bigger is better” approach was
applied (Equation 2). Also; ANOVA was applied at p 0.05 significance level and 95%
confidence level to determine the effects of machining parameters in WEDM of IN718
superalloy.

Process parameters and levels

Exp. No VG (V) LQ (kg/cm2) WS (m/dak)

1 1
2 1
3 1
4 2
5 2
6 2
7 3
8 3
9 3
1 1
2 2
3 3
1 2
2 3
3 1
1 3 Table 4.
2 1 Taguchi L9 (33)
3 2 orthogonal array
 " #
MMMS 1X n
2
18,4 Smaller is better : ¼ −10 log
SN
=
yi (1)
n i¼1
" #
1X n
1
Larger is better : N ¼ −10 log
S =
(2)
n i¼1 yi2
658 In Equation (1) and (2);
yi 5 results of processing parameters
n 5 number of repetitions.

2.2 Taguchi-based Gray Relational Analysis (GRA)

By using the Taguchi Method, only one-criteria optimization can be done. Taguchi-based
GRA method is used to evaluate the degree of relationship between factors by considering
different criteria in cases where uncertainty is in question (Karataş et al., 2020). In GRA,
firstly, data with different units are converted to the same unit and normalized (between 0 and
1). It is important to correctly determine which criterion (“higher is better”, “lower is better” or
“nominal is best”) to use in this normalization process. In this study, “lower is better” given in
Equation (5) for kerf, and for MRR; normalization is performed using the “higher is better”
characteristic given in Equation (6).
maxxi ðkÞ  xi ðkÞ
Lower is better : ni ðkÞ ¼ (5)
maxxi ðkÞ  min xi ðkÞ
xi ðkÞ  minxi ðkÞ
Higher is better : ni ðkÞ ¼ (6)
maxxi ðkÞ  min xi ðkÞ

In Equations (5) and (6);

xi (k) 5 normalized value in k range of i series
max xi (k) 5 maximum value in i series
min xi (k) 5 minimum value in i series
The Gray Relational Coefficient (GRC) (ξi ðkÞ) is determined with the data obtained after the
normalization process (Equation 7) (Karataş et al., 2020).
Δmin þ ξΔmax
ξi ðkÞ ¼ (7)
Δoi ðkÞ þ ξΔmax

In Equation (7);
Δoi ¼ deviation value of the reference array
Δmin 5 minimum value of absolute differences
Δmax 5 maximum value of absolute differences
ξ 5 The coefficient of definition is in the range of 0–1. In this study, ξ 5 0.5 was taken
(Karataş et al., 2020).
After finding the GRC value, the Gray Relational Grade (GRG) is calculated (Equation 8)
(Karataş et al., 2020).
 1X n
Wire EDM
γi ¼ ξ ðkÞ (8)
n k¼1 i cutting of
Inconel 718
In Equation (8);
γ i 5 gray relational degree value of i series
n 5 number of response characteristic. 659
Finally; optimum processing parameters are determined.

2.3 Measurement of cutting width (kerf)

Cutting width (kerf) and spark gap determine the dimensional accuracy of the finished
workpiece in WEDM; it also expresses the amount of material wasted during machining
(Jahan, 2014). Kerf is calculated by adding the wire diameter in the 0.05–0.4 mm range and the
wire-workpiece gap distance (23) (Tosun et al., 2004). In this study, the kerf values formed by
wire electrical discharge cutting of IN718 superalloy were measured using a Dino Capture 2.0
optical microscope with a maximum magnification of 2003. The arithmetic means of the
measurements taken from five different points along the kerf were calculated for the kerf
measurements (Figure 3).

2.4 Measuring the material removal rate (MRR)

Speed and accuracy are essential in machining with WEDM, and cutting speed is very
important during rough cutting (Jahan, 2014). Many attempts have been made to increase
MRR and cutting speed with different approaches to economical machining with WEDM.
MRR in WEDM is highly dependent on material thickness. MRR; although velocity should be
stated in length divided by time, MRR in WEDM is the commonly accepted measurement in
mm3/min, as this measurement depends on part thickness (Jahan, 2014). In this study,
Equation (9) was used to define the amount of material (mm3/min) removed from the sample
by WEDM of the IN718 superalloy.
MRR ¼ vc : b: h (9)

The “vc” given in Equation (9) denotes the cutting speed (mm/min), “b” the kerf (mm) and “h”
the thickness of the workpiece (mm).

Figure 3.
Illustration of the
cutting width (kerf)
measurement after
wire electrical
discharge machining
MMMS 2.5 Microstructure images and energy dispersive spectrometer (EDS) analysis
18,4 Microstructure images of the surfaces were taken to observe the changes in the machined
surface of the IN718 material cut by WEDM. Microstructure images were taken from ZEISS
brand Sigma 300 model SEM (Scanning Electron Microscope) device. Also, the same device
obtained element identification and distribution on the material surface by EDS (Energy-
dispersive X-ray spectroscopy) analysis.
660
3. Results and discussion
The workpiece material’s physical, metallurgical and electrical properties affect the
machining process, and the material’s low melting point increases the cutting speed.
Higher thermal conductivity values and the specific heat capacity of the processed material
reduce the efficiency of WEDM (Jahan, 2014). The main objective to determine the processing
parameters; minimum kerf and maximum MRR (Tosun et al., 2004). A specifically created
investigational procedure is required to assess the effects of processing parameters on kerf
and MRR and to determine performance characteristics under optimum processing
parameters (Chua et al., 1993; Lee and Lee, 2003). This study aims to determine the
optimum values of the cutting parameters to obtain the lowest kerf and the highest MRR due
to the processing of IN718 superalloy on a CNC-controlled WEDM. The Taguchi method was
used to achieve this aim, and the L9 (33) orthogonal array pattern was chosen.

3.1 Experimental results and single criteria optimization with Taguchi Method
Classical experimental design methods are very complex and difficult to use. Also; when the
number of processing parameters increases, many experiments are required (Tosun et al.,
2004). In the Taguchi method, a special orthogonal array design is used to examine the entire
parameter space with only a small number of experiments. In this study, three different
voltages (46, 56 and 66 V), three different dielectric fluid pressures (10, 12 and 14 kg/cm2) and
three different wire feed rates (8, 10 and 12 m/min) were applied to IN718 superalloy. The
current value (10 A) is kept constant. Deionized water was used as dielectric fluid and 0.3 mm
brass wire was used as wire in the experiments. To analyze according to the Taguchi method;
it has been converted to the S/N ratio according to the “smaller is better” approach for the kerf
value and “bigger is better” for the MRR value. While the signal value represents the real
value given by the system and desired to be measured, the noise factor represents the share of
undesired factors in the measured value (Karataş et al., 2020). The kerf and MRR values
obtained after the cutting process are given in Table 5. In the experimental study, the average

VG LQ WS Kerf S/N Kerf MRR S/N MRR

Exp. Nr (V) (kg/cm2) (m/dak) (mm) (dB) (mm3/dak) (dB)

1 46 10 8 0.440 7.1277 27.083 28.6539

2 46 12 10 0.446 7.0141 26.851 28.5791
3 46 14 12 0.452 6.8908 22.099 26.8874
4 56 10 10 0.464 6.6743 19.786 25.9273
5 56 12 12 0.471 6.5322 18.432 25.3116
6 56 14 8 0.462 6.7079 21.787 26.7641
Table 5. 7 66 10 12 0.473 6.5120 11.515 21.2254
Experimental results 8 66 12 8 0.458 6.7827 13.708 22.7393
and S/N ratios obtained 9 66 14 10 0.468 6.6019 12.358 21.8390
according to Taguchi Maximum 0.473 7.1277 27.083 28.6539
L9 (33) Minimum 0.440 6.5120 11.515 21.2254
orthogonal array Average 0.458 6.760 19.291 25.325
kerf value was 0.458 mm, and the average S/N ratio for the average kerf value was 6,760 dB. Wire EDM
The mean MRR value was 19,291 mm3/min and the mean S/N ratio for the mean MRR value cutting of
was 25.325 dB. Some researchers based on the Taguchi experimental design that material
thickness has little effect on MRR and kerf; reported that in order to obtain a good surface
Inconel 718
quality on thinner workpieces, the spark energy will need to be reduced, which will reduce the
MRR (Shah et al., 2011). Ikram et al. also stated that servo voltage and material thickness are
the least significant parameters when machining with WEDM (Ikram et al., 2013). Shah et al.
found that kerf increased at optimum values of MRR (Shah et al., 2011). Ikram et al. 661
determined that pulse-on time and open voltage must be kept at highest level for achieving
greater MRR (Ikram et al., 2013).
The effect of each control factor (VG, LQ and WS) on the kerf and MRR value was
analyzed using the S/N ratio response table. The S/N ratio of each control factor level and how
control factors change from one level to the next are shown (Table 6). Optimum levels were
found by evaluating different levels from all combinations of control factors generated in the
orthogonal array (Karatas et al., 2019). These values “*” are highlighted in Table 6 in italic.
The effect of control factors and levels on kerf and MRR is given in Figure 4. The optimum
level for kerf and MRR values was obtained as VG1LQ2WS1. Bobbili et al. observed that MRR
increased when the pulse-on time was increased and decreased when pulse-off time and servo
voltage were increased (Bobbili et al., 2013). They attributed this to higher thermal power with
an increase in the pulse-on time leading to faster cutting speed (Bobbili et al., 2013). They
determined that the MRR decreased as the servo voltage increased (due to the widening of the
discharge gap). Also, they found that the effects of wire feed, dielectric fluid pressure and wire
tension on MRR were insignificant (Bobbili et al., 2013).
In the wire electrical discharge cutting principle, the materials are processed with the
electric discharge (spark) between the moving wire electrode and the workpiece (Vani et al.,
2018). More than one spark can be observed at one time, and it is important to choose the
processing parameters correctly in order to obtain the material with the desired accuracy. In
this experimental study, optimum values were obtained for kerf and MRR values at low
voltage and low wire feed rate. Kerf plays an important role in designing the tolerance limits
and dimensional accuracy of parts machined using the WEDM method (Rajyalakshmi and
Ramaiah, 2013). The lowest kerf value was obtained from experiment no. 1 (0.440 mm), and
the highest kerf value was obtained from experiment no. 7 (0.473 mm). The highest value of
MRR was 27.083 mm3/min from experiment no. 1, and the lowest value was determined from
experiment no. 7 with 11.515 mm3/min. The decrease of MRR with increasing voltage can be
attributed to the decrease in discharge energy across the electrodes with increasing voltage.
Kumar et al. determined that the most important processing parameters are pulse-on time,
wire feed rate, pulse-off time, current, voltage and wire tension (Kumar et al., 2018a). Pulse-on

Means S/N Ratios

Level VG LQ WS Level VG LQ WS

Kerf (mm) 1 0.446 0.459 0.453 1 7.011* 6.771 6.873*

2 0.466 0.459 0.459 2 6.638 6.776* 6.763
3 0.466 0.461 0.465 3 6.632 6.734 6.645
Difference 0.020 0.002 0.012 Difference 0.379 0.043 0.228
Rank 1 3 2 Rank 1 3 2
MRR (mm3/dak) 1 25.340 19.460 20.860 1 28.040* 25.270 26.050*
2 20.000 19.660 19.670 2 26.000 25.540* 25.450 Table 6.
3 12.530 18.750 17.350 3 21.930 25.160 24.470 Response table of S/N
Difference 12.820 0.920 3.510 Difference 6.110 0.380 1.580 ratios and mean values
Rank 1 3 2 Rank 1 3 2 for kerf and MRR
MMMS
18,4

662

Figure 4.
Graphs for Mean and
S/N Ratios (a) kerf
(b) MRR

time has been reported to be the most important processing parameter for MRR (Goswami
and Kumar, 2014; Kumar et al., 2011; Meena and Azad, 2012). In their study of Inconel,
titanium and aluminum alloys using WEDM, Marelli et al. found an improvement of 1.22 and
5.46%, respectively, in kerf and MRR with optimum cutting parameters (Divya et al., 2020).
In rough-cutting operations; current, pulse-on time, dielectric fluid flow rate and
interactions play an important role in rough-cutting operations; current, pulse-on time,
dielectric fluid flow rate and interactions play an important role (Jahan, 2014; Singh and Garg,
2009). In WEDM, the MRR initially increases with decreasing pulse-off time (Jahan, 2014).
Shah et al. found that MRR decreased with increasing material thickness, pulse-off time and
servo voltage and increased with higher values of open voltage and pulse-on time (Shah et al.,
2011). On the other hand, some researchers stated that MRR is not affected by material
thickness (Luo, 1995). In some studies, it is thought that a lower MRR is obtained in thicker
materials and this is due to insufficient washing due to the longer kerf area (Shah et al., 2011).
In some studies, it was observed that kerf increased with an increase in pulse-on time and
decreased with wire tension (Shah et al., 2011). It has been stated that this results from
reduced wire vibration due to increased tension (Lin et al., 2001).
ANOVA is a statistically based, decision-making tool for detecting any difference in the
average performance of the processing parameters tested (Durairaj et al., 2013; Rao and
Padmanabhan, 2012). The purpose of ANOVA is to investigate to what extent which
processing parameter affects the performance characteristic (Durairaj et al., 2013). In this
study, ANOVA was applied to determine the effect of machining parameters on variable
factors after cutting IN718 superalloy in wire erosion machine. The analysis was performed
at p 0.05 significance level and 95% confidence level (Karataş et al., 2020, 2021). It was
determined which of the factors were effective in the kerf and MRR measurement values and
the effect percentages of the factors. This measurement was made using the Minitab 19
package program. As a result of the experiment, the ANOVA values obtained for kerf and Wire EDM
MRR are shown in Table 7. As shown in the table, the contribution percentages of factors VG, cutting of
LQ and WS to the kerf value were 76.95, 0.79 and 21.46%, respectively, and the percentages of
contributions to the MRR value were 91.21%, 0.51 and 7.01%, respectively. The results show
Inconel 718
that the most effective factors on kerf and MRR are tension and wire feed rate, respectively.
Dielectric fluid pressure had no significant effect. Ikram et al. stated that the significant
parameters for kerf (from the ANOVA) are pulse-on time, wire tension and an open voltage
with a percentage contribution of 49.62, 20.01 and 10.54%, respectively (Ikram et al., 2013). 663
Furthermore, for MRR, the significant factors have been determined pulse on-time, open
voltage and servo voltage having percentage contribution of 47.05, 30.44 and 11.99%,
respectively (Ikram et al., 2013). They found that the factors which are nonsignificant are
material thickness, pulse off-time and dielectric pressure (Ikram et al., 2013).
During the machining of the material, the rapid heating and cooling of the work surface
generates thermal and tensile stress, which causes the formation of some cracks, debris, pits
on the workpiece surface (Daneshmand et al., 2013). To analyze the surface topography of the
processed material, SEM image of the test sample from the first (best) and seventh (worst)
experiments was taken (Figure 5).
The recast layer occurs when molten material is redeposited on the workpiece surface, leading
to micro-cracking (Abhilash and Chakradhar, 2020a). In addition, due to the rapid heating and
cooling of the material surface due to the nature of WEDM processing, debris is formed on the
processed surface by the resolidification of the molten material (Figure 5a and b) (Abhilash and
Chakradhar, 2020a). Debris trapped between processing zones can cause unwanted sparks
(Sivaprakasam et al., 2019). Also, when these debris are not flushed away effectively, the wire
tends to close the spark gap between the electrode and the workpiece (Abhilash and Chakradhar,
2020b). However, the cracking of the surface debris may not be of essential importance since most
of the debris have a weak bond with the sublayer (Chen et al., 2016).
EDS analysis was performed to determine the elemental composition of the machined
surface and to control the zinc and copper migration from the brass wire electrode to the
workpiece (Figure 6a). Nickel (Ni), chromium (Cr), molybdenum (Mo) and niobium (Nb)
obtained from the EDS analysis on surface 1 are due to the chemical composition of the base
material used (Figure 6b). With this, the carbon (C) and oxygen (O) obtained from the EDS
analysis on surface 2 were formed due to the dissociation of deionized water, oxidation
process and spark heat (Figure 6c). Oxidation and/or degradation is directly related to the use
of deionized water as a dielectric (Lauwers et al., 2004). In addition, the presence of copper (Cu)

Variance Contribution
source DF Adj SS Adj MS F-value p-value (%)

Kerf (mm) VG 2 0.000778 0.000389 103.32 0.010 76.95

LQ 2 0.000008 0.000004 1.10 0.476 0.79
WS 2 0.000217 0.000109 28.88 0.033 21.46
Error 2 0.000008 0.000004 0.79
Total 8 0.001011 100.00
Note(s): S 5 0.0019, R2 5 % 99.26, R2 (adj) 5 % 97.02
MRR (mm3/ VG 2 248.691 124.346 71.75 0.014 91.21
dak) LQ 2 1.388 0.694 0.40 0.714 0.51
WS 2 19.115 9.558 5.51 0.153 7.01
Error 2 3.466 1.733 1.27 Table 7.
Total 8 272.661 100.00 ANOVA results for
Note(s): S 5 1.3165 R2 5 % 98.73 R2 (adj) 5 % 94.92 kerf and MRR
MMMS
18,4

664

Figure 5.
SEM image of the
surface obtained from
(a) Exp. No. 1, (b) Exp.
No. 7

Figure 6.
EDS analysis of
machined surfaces
obtained from Exp.
No. 7

and zinc (Zn) elements indicates that material removal during the WEDM process occurs not
only in the workpiece but also in the brass wire (Figure 6c) (Abhilash and Chakradhar, 2020a).

3.2 Taguchi-based Gray Relational Analysis

Gray Relational Analysis (GRA) is a method that analyzes uncertainties in multi-factor
decision-making problems using mathematical methods (Liu et al., 2017). In GRA, black
means no information, white indicates all information and gray shows that there is a level of Wire EDM
knowledge between black and white. So; in a white system, the relationships between the cutting of
factors in the system are certain; in a gray system, the relationships among the factors in the
system are unclear (Julong, 1989; Wang et al., 2001). In the first step of GRA, normalization
Inconel 718
was performed using the “lower is better” characteristic for kerf and “higher is better” for
MRR (Equations 5–6). GRA normalization values are given in Table 8.
Using the normalization values, Gray Relational Coefficient (GRC) values are calculated
(Equation 7). With the help of these values, Gray Relational Grade (GRG) values are 665
calculated (Equation 8). Basically, the greater the gray relational degree, the better the
multiple performance characteristics (Raghuraman et al., 2013; Bilge et al., 2017). The highest
value of GRG implies the best value. Ranking demonstrates the ranking of the best values
according to the GRA. The rank of the highest GRG value is 1. The sequence obtained for the
most ideal sequence is given in Table 9. The rank value is 1, that is; It was determined as the
1st experiment with the highest GRG value. The GRG value of the first experiment was
determined as 1. These results show the optimal experimental sequence for all kerf and MRR
values. While a separate parameter is determined for each result in Taguchi optimization,
GRA gives this optimization common to all results.
The response table for GRG and S/N ratios of GRG is given in Table 10. The graphs of the
GRG and S/N ratio are given in Figure 7. When the S/N ratio is examined in the graph, the
parameters with a high S/N ratio are ideal values. Optimum levels “*” are highlighted in
Table 10 in italic. From here, the most ideal sequence was determined as VG1LQ1WS1. Ideal
conditions were determined as 46 V voltage, 10 kg/cm2 dielectric fluid pressure and 8 mm/min
wire feed rate. An improvement of 6.98 and 57.48% were achieved in kerf and MRR values

Normalization
Exp. No Voltage gap (V) Dielectric liquid pressure (kg/cm2) Wire feed rate (m/dak) Kerf MRR

1 46 10 8 1.0000 1.0000
2 46 12 10 0.8209 0.9851
3 46 14 12 0.6237 0.6798
4 56 10 10 0.2706 0.5313
5 56 12 12 0.0340 0.4443
6 56 14 8 0.3260 0.6598
7 66 10 12 0.0000 0.0000 Table 8.
8 66 12 8 0.4485 0.1408 Gray relation
9 66 14 10 0.1505 0.0541 normalization values

Gray relational coefficient

Exp. No Kerf MRR Gray relational grade Rank

1 1
1 1.0000 1.0000 1.0000 1
2 0.7362 0.9710 0.8536 2
3 0.5706 0.6096 0.5901 3
4 0.4067 0.5162 0.4614 5
5 0.3411 0.4736 0.4074 7
6 0.4259 0.5951 0.5105 4 Table 9.
7 0.3333 0.3333 0.3333 9 Gray relational
8 0.4755 0.3679 0.4217 6 coefficient and gray
9 0.3705 0.3458 0.3582 8 relational degree
MMMS obtained with optimum processing parameters. Accordingly, applying low voltage and low
18,4 feed rate contributed positively to the results. Natarajan and Arunachalam obtained optimum
processing parameters with 100 ms pulse-on time, 4 A current and 20 V voltage in their study
using GRA (Natarajan and Arunachalam, 2011). Mhatre et al. determined optimum
processing parameters with 200 ms pulse-on time, 9 A current and 40 V voltage in their
study using GRA (Mhatre et al., 2014). Thejasree et al. also obtained optimum processing
parameters with 30 ms pulse-on time, 15 ms pulse-off time and 3 A peak current in their study
666 using GRA (Thejasree et al., 2021).
According to the ANOVA analysis of GRG; the most effective parameter affecting all of
the kerf and MRR results was voltage, with an additive value of 77.53% (Table 11). Wire feed
rate was the second effective parameter with a rate of 14.23%. The change in dielectric fluid
pressure did not affect the results much. This situation is consistent with the literature (Tosun
et al., 2004). Also; according to some researchers, it has been concluded that the most effective
parameter in processing with WEDM is the pulse-on time (Rajyalakshmi and Ramaiah, 2013;
Thejasree et al., 2021; Natarajan and Arunachalam, 2011). Natarajan and Arunachalam stated
that pulse-on time was the most important parameter in the ANOVA results for GRG for
multiple performance characteristics (Natarajan and Arunachalam, 2011). Rajyalakshmi and
Ramaiah obtained from the ANOVA results, the pulse-on time is the most important factor

GRG S/N ratio of GRG

Level VG LQ WS Level VG LQ WS

1 0.815 0.598 0.644 1 1.985* 5.420* 4.447*

Table 10. 2 0.460 0.561 0.558 2 6.786 5.558 5.670
Response table for 3 0.371 0.486 0.444 3 8.654 6.446 7.308
GRG and S/N ratios Difference 0.444 0.112 0.201 Difference 6.668 1.026 2.861
of GRG Rank 1 3 2 Rank 1 3 2

Figure 7.
Main effect plots for S/
N ratios of GRG
and GRG

Variance source DF Adj SS Adj MS F-value p-value Contribution (%)

VG 2 0.33048 0.16524 21.19 0.045 77.53

LQ 2 0.01951 0.00975 1.25 0.444 4.58
WS 2 0.06067 0.03033 3.89 0.204 14.23
Table 11. Error 2 0.01559 0.00780 3.66
ANOVA results Total 8 0.42625 100.00
for GRG Note(s): S 5 0.0883, R2 5 % 96.34, R2 (adj) 5 % 85.37
with a contribution of 50.18%, followed by the pulse-off time, wire tension, wire feed, corner Wire EDM
servo voltage, spark gap voltage, and cleaning pressure with contribution rates of 14.19%, cutting of
11.79%, 4.29%, 2.14%, 2.06%, 1.19% and 0.87%, respectively (Rajyalakshmi and Ramaiah,
2013). So that, performance characteristics of the WEDM processes (MRR and kerf) have been
Inconel 718
simultaneously improved together by using GRA.

4. Conclusions
In this comprehensive experimental study, the effect of machining parameters on the kerf and
667
MRR resulting from the machining of IN718 superalloy on a CNC wire electrical discharge
machine was investigated. For this purpose, optimum processing parameters were tried to be
obtained. Furthermore, the GRA method is used to obtain the order of importance and
contribution ratios of the parameters on the multi-objective function. ANOVA analysis was
used to evaluate the experimental results along with the Taguchi technique to optimize the
processing parameters. The findings obtained as a result of the study are listed below:
(1) The lowest kerf value was 0.440 mm, the highest MRR value was 27.083 mm3/min,
and the lowest Ra value was 0.123 mm.
(2) The highest kerf value was 0.473 mm, the lowest MRR value was 11.515 mm3/min and
the highest Ra value was 0.334 mm.
(3) An improvement of 6.98 and 57.48%, respectively, was achieved in the kerf and MRR
values obtained by changing the processing parameters.
(4) The parameter with the highest contribution on the kerf and MRR values of the
control factors was determined as the voltage followed by the wire feed rate. The
contribution rate of the voltage to the kerf and MRR values was 76.95 and 91.21%,
respectively. The contribution rate of the wire feed rate is respectively; 21.46% is
7.01%. Dielectric fluid pressure did not have a significant effect (since p > 0.05).
(5) Optimum conditions for kerf and MRR in WEDM of IN718 superalloy according to
multi-criteria optimization according to Taguchi-based GRA method VG1
LQ1WS1(VG 5 46 V, LQ 5 10 kg/cm2 and WS 5 8 mm/min) has been determined.
(6) Similar to the single-criteria optimization results, according to the multi-criteria
optimization results, the most effective parameters on the kerf and MRR were
respectively the tension and then the wire feed rate. The effect of dielectric fluid
pressure was not statistically significant.
(7) It was observed that the predictive values of the test results of Kerf and MRR results
were in the 95% confidence interval.

References
Abhilash, P. and Chakradhar, D. (2020a), “Surface integrity comparison of wire electric discharge machined
Inconel 718 surfaces at different machining stabilities”, Procedia CIRP, Vol. 87, pp. 228-233.
Abhilash, P. and Chakradhar, D. (2020b), “ANFIS modelling of mean gap voltage variation to predict
wire breakages during wire EDM of Inconel 718”, CIRP Journal of Manufacturing Science and
Technology, Vol. 31, pp. 153-164.
Arunachalam, R., Mannan, M. and Spowage, A. (2004a), “Surface integrity when machining age
hardened Inconel 718 with coated carbide cutting tools”, International Journal of Machine Tools
Manufacture, Vol. 44 No. 14, pp. 1481-1491.
Arunachalam, R., Mannan, M. and Spowage, A. (2004b), “Residual stress and surface roughness when
facing age hardened Inconel 718 with CBN and ceramic cutting tools”, International Journal of
Machine Tools Manufacture, Vol. 44 No. 9, pp. 879-887.
MMMS Bertolini, R., Lizzul, L., Bruschi, S. and Ghiotti, A. (2019), “On the surface integrity of Electron Beam
Melted Ti6Al4V after machining”, Procedia CIRP, Vol. 82, pp. 326-331.
18,4
Bilge, T., Motorcu, A.R. and Ivanov, A. (2017), “Kompakt laminatın delinmesinde boyutsal tamlık için
delme parametrelerinin gri ilişkisel analiz ile optimizasyonu”, Uluslararası Teknolojik Bilimler
Dergisi, Vol. 9 No. 2, pp. 1-22.
Bobbili, R., Madhu, V. and Gogia, A. (2013), “Effect of wire-EDM machining parameters on surface
roughness and material removal rate of high strength armor steel”, Materials Manufacturing
668 Processes, Vol. 28 No. 4, pp. 364-368.
Chen, Z., Moverare, J., Peng, R.L. and Johansson, S. (2016), “Surface integrity and fatigue performance
of Inconel 718 in wire electrical discharge machining”, Procedia CIRP, Vol. 45, pp. 307-310.
Chua, M.S., Rahman, M., Wong, Y.S. and Loh, H.T. (1993), “Determination of optimal cutting
conditions using design of experiments and optimization techniques”, International Journal of
Machine Tools Manufacture, Vol. 33 No. 2, pp. 297-305.
Coelho, R.T., Silva, L.R., Braghini, A., Jr. and Bezerra, A.A. (2004), “Some effects of cutting edge
preparation and geometric modifications when turning INCONEL 718TM at high cutting
speeds”, Journal of Materials Processing Technology, Vol. 148 No. 1, pp. 147-153.
Courbon, C., Kramar, D., Krajnik, P., Pusavec, F., Rech, J. and Kopac, J. (2009), “Investigation of
machining performance in high-pressure jet assisted turning of Inconel 718: an experimental
study”, International Journal of Machine Tools Manufacture, Vol. 49 No. 14, pp. 1114-1125.
Daneshmand, S., Kahrizi, E.F., Abedi, E. and Abdolhosseini, M.M. (2013), “Influence of machining
parameters on electro discharge machining of NiTi shape memory alloys”, International Journal
of Electrochemical Science, Vol. 8 No. 3, pp. 3095-3104.
Darwish, S. (2000), “The impact of the tool material and the cutting parameters on surface roughness
of supermet 718 nickel superalloy”, Journal of Materials Processing Technology, Vol. 97 Nos 1-3,
pp. 10-18.
Dhanunjaya, M., Madduleti, M. and Boosa, G.C. (2018), “The process of EDM cutting parameters
optimizing by using Taguchi Method and Anova on Inconel 718”, International Research
Journal of Engineering and Technology, Vol. 5 No. 12, pp. 1305-1311.
Divya, M., Sateesh, N. and Subbiah, R. (2020), “Review on multi objective optimization of wire cut
EDM process parameters using grey relational analysis”, Materials Today: Proceedings, Vol. 26,
pp. 3124-3130.
Donachie, M.J. and Donachie, S.J. (2002), Superalloys: A Technical Guide, 2nd ed., ASM international.
Dudzinski, D., Devillez, A., Moufki, A., Larrouquere, D., Zerrouki, V. and Vigneau, J. (2004), “A review
of developments towards dry and high speed machining of Inconel 718 alloy”, International
Journal of Machine Tools Manufacture, Vol. 44 No. 4, pp. 439-456.
Durairaj, M., Sudharsun, D. and Swamynathan, N. (2013), “Analysis of process parameters in wire
EDM with stainless steel using single objective Taguchi method and multi objective grey
relational grade”, Procedia Engineering, Vol. 64, pp. 868-877.
Ekici, E., Motorcu, A.R. and Kuş, A. (2016), “Evaluation of surface roughness and material removal
rate in the wire electrical discharge machining of Al/B4C composites via the Taguchi method”,
Journal of Composite Materials, Vol. 50 No. 18, pp. 2575-2586.
Ezugwu, E. and Tang, S. (1995), “Surface abuse when machining cast iron (G-17) and nickel-base
superalloy (Inconel 718) with ceramic tools”, Journal of Materials Processing Technology, Vol. 55
No. 2, pp. 63-69.
Ezugwu, E., Wang, Z. and Okeke, C. (1999), “Tool life and surface integrity when machining Inconel
718 with PVD-and CVD-coated tools”, Tribology Transactions, Vol. 42 No. 2, pp. 353-360.
Garg, M., Kumar, A. and Sahu, C. (2017), “Mathematical modeling and analysis of WEDM machining
parameters of nickel-based super alloy using response surface methodology”, Sadhana, Vol. 42
No. 6, pp. 981-1005.
Goswami, A. and Kumar, J. (2014), “Investigation of surface integrity, material removal rate and wire Wire EDM
wear ratio for WEDM of Nimonic 80A alloy using GRA and Taguchi method”, Engineering
Science Technology an International Journal, Vol. 17 No. 4, pp. 173-184. cutting of
Ikram, A., Mufti, N.A., Saleem, M.Q. and Khan, A.R. (2013), “Parametric optimization for surface
Inconel 718
roughness, kerf and MRR in wire electrical discharge machining (WEDM) using Taguchi
design of experiment”, Journal of Mechanical Science Technology, Vol. 27 No. 7, pp. 2133-2141.
Jahan, M.P. (2014), Electrical Discharge Machining (EDM): Types, Technologies and Applications, Nova
Science Publishers, New York. 669
Julong, D. (1989), “Introduction to grey system theory”, The Journal of Grey System, Vol. 1
No. 1, pp. 1-24.
Karatas, M.A., Gokkaya, H. and Nalbant, M. (2019), “Optimization of machining parameters for
abrasive water jet drilling of carbon fiber-reinforced polymer composite material using Taguchi
method”, Aircraft Engineering Aerospace Technology, Vol. 92 No. 2, pp. 128-138.
Karataş, M.A., Motorcu, A.R. and G€okkaya, H. (2020), “Optimization of machining parameters for kerf
angle and roundness error in abrasive water jet drilling of CFRP composites with different fiber
orientation angles”, Journal of the Brazilian Society of Mechanical Sciences Engineering, Vol. 42
No. 4, pp. 1-27.
Karataş, M.A., Motorcu, A.R. and G€okkaya, H. (2021), “Study on delamination factor and surface
roughness in abrasive water jet drilling of carbon fiber-reinforced polymer composites with
different fiber orientation angles”, Journal of the Brazilian Society of Mechanical Sciences
Engineering, Vol. 43 No. 1, pp. 1-29.
Kitagawa, T., Kubo, A. and Maekawa, K. (1997), “Temperature and wear of cutting tools in high-speed
machining of Inconel 718 and Ti6Al6V2Sn”, Wear, Vol. 202 No. 2, pp. 142-148.
Kumar, A. and Singh, S. (2021), “Parametric optimization of wire electro discharge machining of
Inconel 718 using Taguchi’s methodology”, Materials Today: Proceedings, Vol. 43,
pp. 2025-2031.
Kumar, A., Maheshwari, S., Sharma, C. and Beri, N. (2011), “Analysis of machining characteristics in
additive mixed electric discharge machining of nickel-based super alloy Inconel 718”, Materials
Manufacturing Processes, Vol. 26 No. 8, pp. 1011-1018.
Kumar, P., Meenu, M. and Kumar, V. (2018a), “Optimization of process parameters for WEDM of
Inconel 825 using grey relational analysis”, Decision Science Letters, Vol. 7 No. 4, pp. 405-416.
Kumar, A., Abhishek, K., Vivekananda, K. and Maity, K.P. (2018b), “Effect of wire electrode materials
on die-corner accuracy for Wire Electrical Discharge Machining (WEDM) of Inconel 718”,
Materials Today: Proceedings, Vol. 5 No. 5, pp. 12641-12648.
Kuş, A. and Motorcu, A.R. (2017), “Nikel esaslı was paloy alaşımının tel erozyon y€ontemiyle
işlenmesinde Taguchi metodu ile y€ uzey p€
ur€uzl€
ul€
ugu
€ için optimum kesme parametrelerinin
tahmini”, Journal of the Faculty of Engineering Architecture of Gazi University, Vol. 32 No. 1,
pp. 195-204.
Lauwers, B., Kruth, J.P., Liu, W., Eeraerts, W., Schacht, B. and Bleys, P. (2004), “Investigation of
material removal mechanisms in EDM of composite ceramic materials”, Journal of Materials
Processing Technology, Vol. 149 Nos 1-3, pp. 347-352.
Lee, S.H. and Lee, S.-H. (2003), “Optimisation of cutting parameters for burr minimization in face-
milling operations”, International Journal of Production Research, Vol. 41 No. 3, pp. 497-511.
Li, L., Guo, Y.B., Wei, X.T. and Li, W. (2013), “Surface integrity characteristics in wire-EDM of Inconel
718 at different discharge energy”, Procedia CIRP, Vol. 6, pp. 220-225.
Li, L., He, N., Wang, M. and Wang, Z.G. (2002), “High speed cutting of Inconel 718 with coated carbide
and ceramic inserts”, Journal of Materials Processing Technology, Vol. 129 Nos 1-3, pp. 127-130.
Liao, Y. and Shiue, R. (1996), “Carbide tool wear mechanism in turning of Inconel 718 superalloy”,
Wear, Vol. 193 No. 1, pp. 16-24.
MMMS Lin, J. and Tarng, Y. (1998), “Optimization of the multi-response process by the Taguchi method with
grey relational analysis”, Journal of Grey System, Vol. 4 No. 4, pp. 355-370.
18,4
Lin, C.-T., Chung, I.-F. and Huang, S.-Y. (2001), “Improvement of machining accuracy by fuzzy logic at
corner parts for wire-EDM”, Fuzzy Sets Systems, Vol. 122 No. 3, pp. 499-511.
Lin, J.L., Wang, K.S., Yan, B.H. and Tarng, Y.S. (2000), “Optimization of the electrical discharge
machining process based on the Taguchi method with fuzzy logics”, Journal of Materials
Processing Technology, Vol. 102 Nos 1-3, pp. 48-55.
670
Liu, S., Yang, Y. and Forrest, J. (2017), “Grey data analysis”, Springer Singapore, Vol. 10 No. 1007,
pp. 978-981.
at, N. and Josefson, B. (2009), “Modelling chip formation of alloy 718”, Journal of
Lorentzon, J., J€arvstr
Materials Processing Technology, Vol. 209 No. 10, pp. 4645-4653.
Luo, Y. (1995), “An energy-distribution strategy in fast-cutting wire EDM”, Journal of Materials
Processing Technology, Vol. 55 Nos 3-4, pp. 380-390.
Mahapatra, S. and Patnaik, A. (2007), “Optimization of wire electrical discharge machining (WEDM)
process parameters using Taguchi method”, The International Journal of Advanced
Manufacturing Technology, Vol. 34 Nos 9-10, pp. 911-925.
Meena, V.K. and Azad, M.S. (2012), “Grey relational analysis of micro-EDM machining of Ti-6Al-4V
alloy”, Materials Manufacturing Processes, Vol. 27 No. 9, pp. 973-977.
Mhatre, M.S., Sapkal, S.U. and Pawade, R.S. (2014), “Electro discharge machining characteristics of Ti-
6Al-4V alloy: a grey relational optimization”, Procedia Materials Science, Vol. 5, pp. 2014-2022.
Mitrofanov, A., Babitsky, V. and Silberschmidt, V. (2004), “Finite element analysis of ultrasonically
assisted turning of Inconel 718”, Journal of Materials Processing Technology, Vol. 153, pp. 233-239.
Natarajan, N. and Arunachalam, R. (2011), “Optimization of micro-EDM with multiple performance
characteristics using Taguchi method and Grey relational analysis”, Journal of Scientific and
Industrial Research (JSIR), Vol. 70 No. 7, pp. 500-505.
Patel, K., Pandey, P.M. and Rao, P.V. (2010), “Optimisation of process parameters for multi-
performance characteristics in EDM of Al 2 O 3 ceramic composite”, The International Journal
of Advanced Manufacturing Technology, Vol. 47 Nos 9-12, pp. 1137-1147.
Newton, T.R., Melkote, S.N., Watkins, T.R., Trejo, R.M. and Reister, L. (2009), “Investigation of the
effect of process parameters on the formation and characteristics of recast layer in wire-EDM of
Inconel 718”, Materials Science Engineering: A, Vol. 513, pp. 208-215.
Patel, V.D., Patel, D.M., Patel, U.J., Patel, B. and Butani, N. (2014), “Review of wire-cut EDM process on
titanium alloy”, International Journal of Engineering Research and Applications, Vol. 4 No. 12,
pp. 112-121.
Pawade, R., Joshi, S.S. and Brahmankar, P. (2008), “Effect of machining parameters and cutting edge
geometry on surface integrity of high-speed turned Inconel 718”, International Journal of
Machine Tools Manufacture, Vol. 48 No. 1, pp. 15-28.
Pawade, R.S., Joshi, S.S., Brahmankar, P.K. and Rahman, M. (2007), “An investigation of cutting forces
and surface damage in high-speed turning of Inconel 718”, Journal of Materials Processing
Technology, Vol. 192, pp. 139-146.
Raghuraman, S., Thiruppathi, K., Panneerselvam, T. and Santosh, S. (2013), “Optimization of EDM
parameters using Taguchi method and grey relational analysis for mild steel IS 2026”,
International Journal of Innovative Research in Science, Engineering Technology, Vol. 2 No. 7,
pp. 3095-3104.
Rahman, M., Seah, W. and Teo, T. (1997), “The machinability of Inconel 718”, Journal of Materials
Processing Technology, Vol. 63 Nos 1-3, pp. 199-204.
Rajyalakshmi, G. and Ramaiah, P.V. (2013), “Multiple process parameter optimization of wire electrical
discharge machining on Inconel 825 using Taguchi grey relational analysis”, The International
Journal of Advanced Manufacturing Technology, Vol. 69 Nos 5-8, pp. 1249-1262.
Rao, S.R. and Padmanabhan, G. (2012), “Application of Taguchi methods and ANOVA in optimization Wire EDM
of process parameters for metal removal rate in electrochemical machining of Al/5% SiC
composites”, International Journal of Engineering Research Applications, Vol. 2 No. 3, cutting of
pp. 192-197. Inconel 718
Shah, A., Mufti, N.A., Rakwal, D. and Bamberg, E. (2011), “Material removal rate, kerf, and surface
roughness of tungsten carbide machined with wire electrical discharge machining”, Journal of
Materials Engineering Performance, Vol. 20 No. 1, pp. 71-76.
Shandilya, P., Rouniyar, A.K. and Saikiran, D. (2020), “Multi-objective parametric optimization on 671
machining of Inconel-825 using wire electrical discharge machining”, Proceedings of the
Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, Vol. 234
No. 20, pp. 4056-4068.
Sharman, A., Hughes, J. and Ridgway, K. (2004), “Workpiece surface integrity and tool life issues
when turning Inconel 718™ nickel based superalloy”, Machining Science Technology, Vol. 8
No. 3, pp. 399-414.
Sharman, A., Hughes, J. and Ridgway, K. (2006), “An analysis of the residual stresses generated in
Inconel 718™ when turning”, Journal of Materials Processing Technology, Vol. 173 No. 3,
pp. 359-367.
Sharman, A., Hughes, J. and Ridgway, K. (2008), “Surface integrity and tool life when turning Inconel
718 using ultra-high pressure and flood coolant systems”, Proceedings of the Institution
of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 222 No. 6,
pp. 653-664.
Sheth, M., Gajjar, K., Jain, A., Shah, V., Patel, H., Chaudhari, R. and Vora, J. (2021), “Multi-objective
optimization of inconel 718 using combined approach of taguchi—grey relational analysis”,
Advances in Mechanical Engineering, Springer, pp. 229-235.
Singh, S. and Bhardwaj, A. (2011), “Review to EDM by using water and powder-mixed dielectric
fluid”, Journal of Minerals Materials Characterization Engineering, Vol. 10 No. 02, p. 199.
Singh, H. and Garg, R. (2009), “Effects of process parameters on material removal rate in WEDM”,
Journal of Achievements in Materials Manufacturing Engineering, Vol. 32 No. 1, pp. 70-74.
Sivaprakasam, P., Hariharan, P. and Gowri, S. (2019), “Experimental investigations on nano powder
mixed Micro-Wire EDM process of inconel-718 alloy”, Measurement, Vol. 147, p. 106844.
Thejasree, P., Binoj, J.S., Manikandan, N., Krishnamachary, P.C., Raju, R. and Palanisamy, D. (2021),
“Multi objective optimization of wire electrical discharge machining on Inconel 718 using
Taguchi grey relational analysis”, Materials Today: Proceedings, Vol. 39, pp. 230-235.
Tosun, N., Cogun, C. and Tosun, G. (2004), “A study on kerf and material removal rate in wire
electrical discharge machining based on Taguchi method”, Journal of Materials Processing
Technology, Vol. 152 No. 3, pp. 316-322.
Ulutan, D. and Ozel, T. (2011), “Machining induced surface integrity in titanium and nickel alloys: a
review”, International Journal of Machine Tools Manufacture, Vol. 51 No. 3, pp. 250-280.
Vani, P.N., Arun, K., Reddy, M.C.S. and Madduleti, M. (2018), “Optimizing the Process Parameters of
EDM Using Taguchi Method and Anova on Inconel 718”, Journal of Emerging Technologies and
Innovative Research (JETIR), Vol. 5 No. 12, pp. 487-494.
Wang, C., Chen, S.-F. and Yuen, M.M.F. (2001), “Fuzzy part family formation based on grey relational
analysis”, The International Journal of Advanced Manufacturing Technology, Vol. 18 No. 2,
pp. 128-132.
Varol Ozkavak, H., Sofu, M.M., Duman, B. and Bacak, S. (2021), “Estimating surface roughness for
different EDM processing parameters on Inconel 718 using GEP and ANN”, CIRP Journal of
Manufacturing Science and Technology, Vol. 33, pp. 306-314.
Wang, F., Liu, Y., Shen, Y., Ji, R., Tang, Z. and Zhang, Y. (2013), “Machining performance of Inconel
718 using high current density electrical discharge milling”, Materials Manufacturing Processes,
Vol. 28 No. 10, pp. 1147-1152.
MMMS Welling, D. (2014), “Results of surface integrity and fatigue study of wire-EDM compared to broaching
and grinding for demanding jet engine components made of Inconel 718”, Procedia CIRP,
18,4 Vol. 13, pp. 339-344.
Yang, C.-B., Lin, C.-G., Chiang, H.-L. and Chen, C.-C. (2017), “Single and multiobjective optimization of
Inconel 718 nickel-based superalloy in the wire electrical discharge machining”, The
International Journal of Advanced Manufacturing Technology, Vol. 93 No. 9, pp. 3075-3084.

672
Corresponding author
Meltem Altin Karataş can be contacted at: meltemaltin@ibu.edu.tr

For instructions on how to order reprints of this article, please visit our website:
www.emeraldgrouppublishing.com/licensing/reprints.htm
Or contact us for further details: permissions@emeraldinsight.com