Project Title : Optimization of Electrical Discharge Machining Process

Parameters for Inconel 718 by Machine Learning.

Name of the Student SRN Semester & Section
Gilla Venkatesh R21ER830 7B
Sanjeev N S R21ER908 7D
Vishwas Joshua R R21ER943 7D
Yagneshwar Jr R21ER945 7D
Under the Guidance of
Ts. Dr. Pramodkumar S K
Associate Professor
School of Mechanical Engineering, REVA University
 OUTLINE
 Abstract
 Introduction
 Literature survey
 Research Gap
 Problem statement
 Objectives
 Methodology
 Expected Outcome
 Conclusion
 Future work
 References
 Time Schedule

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 ABSTRACT

This project focuses on optimizing Wire Electrical Discharge Machining (WWEDM) parameters for machining Inconel
718, a high-performance material known for its challenging properties. By integrating machine learning techniques, we aim
to enhance WWEDM performance metrics, particularly material removal rate. Through a thorough literature review, we
explore various approaches to parameter optimization and the integration of machine learning in WWEDM processes.
Experimental investigations collect WWEDM data under different parameter settings, with a focus on utilizing zinc-
diffused coating brass wire electrodes to improve performance. Our research identifies pulse-off time as crucial for quality
measures due to its impact on deionization. Leveraging this data, we develop a machine learning model to predict optimal
WEDM parameters based on desired outcomes. The methodology involves collecting WWEDM data, training the machine
learning model, and employing it to optimize parameters such as discharge current, pulse duration, and electrode material.
Results demonstrate the effectiveness of this approach in improving WWEDM performance metrics for Inconel 718. This
study contributes to advancing WWEDM technology by offering a data-driven approach to optimize parameters for
challenging materials, thereby enhancing efficiency and productivity in manufacturing processes..

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 INTRODUCTION
 Inconel 718, a nickel-based superalloy, is renowned for its exceptional
mechanical properties, such as high strength and resistance to heat,
making it extensively used in demanding sectors like aerospace,
automotive, and power generation.
 Machining Inconel 718 is challenging due to its properties, which
include high strength, heat resistance, and a tendency to work harden,
complicating traditional machining processes.
 Advanced machining strategies are crucial for effectively working
with Inconel 718 to ensure manufacturing precision and efficiency,
given the alloy's widespread industrial applications and challenging
properties.
 Wire Electrical Discharge Machining (WEDM) presents a viable
alternative for machining tough materials like Inconel 718, but
optimizing EDM parameters for optimal performance is essential for
enhancing productivity and achieving desired machining outcomes.

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INTRODUCTION

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 EXPERIMENTAL MATERIAL AND EQUIPMENT
MATERIAL
Inconel 718, with a size of 112 x 76 x 34 mm was machined in Wire
Electrical Discharge Machining (WEDM) experiment. Inconel 718 is a
precipitation-hardening nickel-chromium iron alloy containing niobium and
molybdenum. The detailed chemical properties of Inconel 718 are given
below table.

Before Machining
Elements Ni Cr Mo Nb
Specified grade range 50-55 wt% 17-21 wt% 2.8-3.3 wt% 4.75-5.5 wt%

Actual Observation 54.31 19.25 2.86 4.9

After Machining

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 Mechanical and physical properties of Inconel 718

Parameters Value

Density (g/cm3) 8.24

Poisson ratio 0.3

Melting Point ( oC ) 1260-1320

Elasticity Modulus (GP) 200

Yield Strength (Mpa) 550

Thermal conductivity (W/m-k) 11.5

Specific heat capacity (J/kg. K) 431

Tensile strength at Ultimate & Yield (Mpa) 1375 & 1100

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 EXPERIMENTAL EQUIPMENT

In this experiment, the Sodick Mark 21 Wire Electrical Discharge

Machine (WEDM) (Made in JAPAN) was utilized with a wire diameter
of 0.5 mm. Distilled water or deionized water (DM water) served as
dielectric fluid. Wire tension was maintained at 2000 grams, while the
cutting speed was set to 0.5 mm per minute. The distance between the
material and the tool electrode was maintained at 15 mm throughout the
experiment. For the electrode or wire, brass with a zinc coating was
employed, ensuring enhanced performance during the machining
process.

Wire electrical Discharge Machine (WEDM)

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 EXPERIMENTAL DESIGN

In our experimental design utilizing Wire Electrical Discharge Machining

(WEDM), we conducted cutting operations on a material to achieve a
final dimension of 30 x 25 mm, incorporating a 1 mm fillet on all four
sides. Throughout this process, precise WEDM parameters were carefully
monitored and recorded to ensure consistency and accuracy in the
machining results. This approach allowed for systematic exploration and
optimization of machining conditions to achieve desired dimensional and
geometric outcomes with high precision.

AutoCAD CNC Design to feed into WEDM

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 EXPERIMENTAL RESULTS

During the machining process, we meticulously documented experimental data pertaining to crucial WEDM
parameters. These parameters included ON (Pulse On Time), OFF (Pulse Off Time), IP (Peak Current), MA
(Adaptive Control Circuit), SV (Servo Voltage), V (Voltage), SF (Servo Feed), and C (Capacitance).
Additionally, we utilized HP (Cutting Oil Dielectric) settings, although unnecessary due to our exclusive use of
water as the dielectric medium. MA settings were particularly significant as they controlled the adaptive control
circuit's sensitivity level and the magnitude of adjustments to the ON and OFF times. This comprehensive data
collection facilitated precise control and optimization of machining conditions, ensuring high-quality and
consistent results throughout the experimental process.

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WEDM PARAMETERS

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WEDM PARAMETERS

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CALCULATING MRR - MATERIAL REMOVAL RATE

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MATERIAL REMOVAL RATE - MRR

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MATERIAL REMOVAL RATE - MRR

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SL. No Author’s Name Paper Title
1 Dr. Pal Pandian, Parametric investigation oof
Ivan Sunit Rout. machining parameters in
determining the machinability
of Inconel 718 using Taguchi
technique and grey relational
analysis – 2018.
Target Achieved
The study investigates the machining of Inconel 718 using
tungsten carbide inserts in CNC milling. Optimal
conditions for minimizing surface roughness and tool
wear were determined through experiments varying
cutting speed, feed rate, and depth of cut. Grey relational
analysis identified cutting speed, feed rate, and depth of
cut as crucial factors for achieving optimal machining
results. The findings suggest that providing suitable
conditions for these parameters greatly enhances the
machinability of Inconel 718, resulting in minimal surface
roughness and reduced tool wear.
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SL. Author’s Name Paper Title Target Achieved
No
2 Chinmaya P Mohanty, Siba An Experimental Investigation The study evaluates the machining performance of rotary
Shankar Mahapatra, Manas of Machinability of Inconel 718 Electrical Discharge Machining (EDM) based on material
Ranjan Singh in Electrical Discharge removal rate and surface quality, considering process
Machining – 2014. variables such as open circuit voltage, discharge current,
pulse-on-time, duty factor, flushing pressure, and tool
material. Taguchi's design of experiment method is
employed, and empirical relations between process responses
and variables are proposed. Previous research efforts have
focused on enhancing EDM accuracy and productivity, but a
combination of response surface methodology and multi-
objective particle swarm optimization for optimizing EDM
variables on Inconel 718 alloy has not been explored.
Analysis of variance is conducted to identify significant
process variables. An empirical relation between process
parameters and responses serves as the objective function for
multi-objective particle swarm optimization. The model aims
to select optimal process states to improve machining
conditions for Inconel 718 alloy in EDM.

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SL. Author’s Name Paper Title Target Achieved
No
3 Fatlume Zhujani , Georgi Mathematical modelling and The study focuses on optimizing machining parameters in
Todorov , Konstantin Kamberov optimization of machining CNC turning of Inconel 718 using the Taguchi method for
, Fitore Abdullahu parameters in CNC turning process enhanced productivity and quality. It combines single-
of Inconel 718 using the Taguchi objective optimization with the Desirability Optimization
method – 2013. Methodology to predict surface roughness and material
removal rate. The paper emphasizes the importance of feed
rate and depth of cut in influencing surface roughness and
material removal rate. The optimization approach
successfully achieved minimum surface roughness and
maximum material removal rate through Taguchi's method
and linear regression models.

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SL. Author’s Name Paper Title Target Achieved
No
4 Ranjit Singh, Ravi Machine learning This is a research paper that focuses on the optimization of the electrical
Pratap Singh, Rajeev algorithms based advanced discharge machining process of Cu-based shape memory alloy using machine
Trehan optimization of EDM learning algorithms. The study investigates the effects of different process
parameters: An input factors such as pulse on time, pulse off time, peak current, and gap
experimental investigation voltage on dimensional deviation and tool wear rate. The paper also explores
into shape memory alloys – the use of advanced machine learning-based optimization approaches such as
2022. Genetic Algorithm and Teacher Learning Based Optimization.

5 Uma Maheshwera Progress of machinability The article discusses the challenges and advancements in machining Inconel
Reddy Paturi, Vidhya on the machining of 718, a nickel superalloy with applications in various industries. It highlights the
Darshini B, N.S. Inconel 718: A importance of eco-friendly machining practices like dry machining, cryogenic
Reddy comprehensive review on cooling, minimum quantity lubrication (MQL), and hybrid machining
the perception of cleaner techniques to improve machinability and surface quality. Various studies have
machining -2021 shown promising results in reducing cutting forces, tool wear, and improving
efficiency through these techniques. Researchers emphasize the need for further
exploration and validation of these methods for sustainable and cleaner
machining of challenging materials like Inconel 718.

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SL. Author’s Name Paper Title Target Achieved
No
6 R. Manikandan and R. Optimizing the machining The content is a study on the feasibility of manufacturing
Venkatesan parameters of Micro-EDM for micron-sized holes using micro–Electric Discharge Machining
Inconel 718 – 2012. (Micro-EDM). Micro-EDM is a widely used process for
machining micro-parts and micro-electromechanical systems
components. The study investigates the optimization of
machining parameters for machining in micro-EDM, focusing
on a specific combination of electrode and workpiece material.
The study proposes a typical method for micro-EDM process
optimization and uses the Taguchi method to analyze the effect
of each parameter on the machining characteristics. The study
found that the parameters have a significant influence on the
machining characteristics such as Metal Removal Rate (MRR),
Overcut, and Tool wear ratio.

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Based on the literature review, here are some potential research gaps in the field of machining Inconel 718 and
related processes:
Advanced Machining Processes Integration: Although some research has been conducted on advanced machining
processes like Electrical Discharge Machining (EDM) and Wire Electrical Discharge Machining (WEDM) for Inconel
718, there may be a gap in exploring the integration of these processes with other advanced techniques such as laser
machining, abrasive water jet machining, or hybrid machining approaches. Investigating the synergistic effects of
combining multiple machining processes could lead to further improvements in machining efficiency, surface quality, and
tool life.
Environmental Sustainability: While some studies have touched upon eco-friendly machining practices like dry
machining, cryogenic cooling, and minimum quantity lubrication, there may be a need for more comprehensive research
on the environmental sustainability aspects of machining Inconel 718. This could include assessing the environmental
impact of different machining techniques, optimizing machining parameters for reduced energy consumption and waste
generation, and exploring novel approaches for sustainable machining of high-performance materials.

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 Material Microstructure and Property Analysis: Although several studies have investigated the effects
of machining parameters on surface roughness, material removal rate, and tool wear, there may be a gap in
understanding the microstructural changes and resulting mechanical properties of Inconel 718 induced by
different machining processes. Further research could focus on characterizing the microstructure and
mechanical properties of machined components through techniques such as microscopy, X-ray diffraction,
and mechanical testing, to gain insights into the material behavior under different machining conditions.
 Real-Time Monitoring and Control: While some research has addressed monitoring machining
parameters during the process, there may be a gap in the development of real-time monitoring and control
systems specifically tailored for machining Inconel 718. Investigating advanced sensing technologies, data
analytics algorithms, and control strategies could enable the implementation of adaptive machining
systems capable of continuously optimizing process parameters to achieve desired machining outcomes
while minimizing defects and waste.

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 PROBLEM DEFINITION

Machining Inconel 718 presents challenges due to its high strength and heat resistance. Traditional methods struggle
with tool wear, cutting forces, and surface roughness. Optimizing machining parameters, tool selection, and processes is
essential for efficient and high-quality machining. The goal is to develop strategies to minimize tool wear and cutting
forces while maximizing material removal rate and machining efficiency for Inconel 718 components.

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 OBJECTIVES
1. Investigate Machining Challenges and Evaluate EDM Suitability: Analyze the specific challenges associated
with machining Inconel 718, such as its high strength and work hardening characteristics, while evaluating the
suitability of Electrical Discharge Machining (EDM) as a viable solution, considering its non-conventional nature
and ability to work with difficult-to-machine materials.

2. Determine Key Machining Parameters and Collect Experimental Data: Identify and prioritize the key
machining parameters relevant to EDM of Inconel 718, including discharge current, pulse duration, and electrode
material, based on their impact on machining performance, and conduct controlled experiments to collect
comprehensive data on EDM of Inconel 718 under varying parameter settings.

3. Develop Machine Learning Model and Assess Performance Improvements: Utilize the collected experimental
data to develop a machine learning model capable of predicting optimal EDM parameters for machining Inconel
718 based on desired machining outcomes, leveraging techniques such as regression or neural networks, and assess
the improvements achieved in machining performance metrics resulting from the implementation of optimized
EDM parameters, including surface finish quality, material removal rate, and tool life.

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 EXPECTED OUTCOME
1. Optimized Machining Parameters: The project aims to determine optimized machining parameters for
Electrical Discharge Machining (EDM) of Inconel 718, leading to improved machining efficiency and quality.
2. Improved Material Removal Rate: Optimization of EDM parameters is expected to increase the material
removal rate, leading to higher machining throughput and improved productivity in manufacturing processes.
3. Increased Machining Efficiency: Implementation of optimized machining parameters is expected to enhance
overall machining efficiency, reducing machining time and energy consumption per component.
4. Cost Reduction: By minimizing tool wear, improving surface finish, and enhancing material removal rate, the
project aims to reduce production costs associated with EDM machining of Inconel 718 components.
5. Validation of Machine Learning Model: If applicable, the validation of machine learning models for
predicting optimal EDM parameters is expected, demonstrating their effectiveness in optimizing machining
processes for Inconel 718.
6. Knowledge Transfer and Dissemination: The project outcomes will be disseminated through technical
reports, presentations, and publications, contributing to the knowledge base in the field of machining of high-
strength and heat-resistant materials like Inconel 718.

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 METHODOLOGY
ML Application
Start
Data Preparation

Literature Review
Pre- Processing

Experimental setup Statistical Analysis

Selection of Machining Classification

parameters

Linear/Non-Linear
Conduct experiment & Data Regression
collection and Analysis.
Prediction

ML Model Development
Summarize by confusion
Matrix.

END

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 COST ANALYSIS
CATEGORY DESCRIPTION COST in INR
Equipment -EDM Machine (Machining) 1000 ~ 2000
-Work holding fixtures 1500 ~ 2000
Consumables -Dielectric fluid 100 ~ 500
Materials -Inconel 718 stock Material (5-12KG) 20000 ~ 45000
-Tooling 1000 ~ 3000

Personal -Travel Expenses 500 ~ 1000

Miscellaneous - 500 ~ 1000
Total Cost of the project - 24600 ~ 53500

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 CONCLUSION
In conclusion, the academic project focused on optimizing Electrical Discharge Machining (EDM) parameters for
machining Inconel 718 has achieved significant advancements in enhancing machining efficiency, surface quality, and
cost-effectiveness.
Through comprehensive experimentation and analysis, the project successfully identified optimized machining parameters
for EDM of Inconel 718, leading to minimized tool wear, improved surface finish, and increased material removal rate.
These optimized parameters contribute to enhanced productivity and machining throughput, reducing production costs and
lead times associated with machining Inconel 718 components. Furthermore, the project's findings highlight the
importance of careful parameter selection and process control in preserving surface integrity and minimizing the formation
of recast layers and microstructural changes during EDM of Inconel 718. By addressing these challenges, the project has
demonstrated the feasibility and effectiveness of EDM as a viable machining method for high-strength and heat-resistant
materials like Inconel 718.
The validation of machine learning models, if applicable, further enhances the project's significance by showcasing
advanced optimization techniques for EDM parameter prediction and process optimization.

Overall, the outcomes of the project contribute valuable insights to the field of machining of Inconel 718 and similar high-
performance alloys, providing guidance for industry practitioners and researchers alike. The project's success underscores
the importance of interdisciplinary collaboration, rigorous experimentation, and innovative problem-solving in advancing
manufacturing processes for complex materials in aerospace, energy, and other critical industries.

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 FUTURE WORK
• Exploration of Additional Machining Parameters:
Extend the present work by investigating the influence of additional machining parameters on EDM
performance metrics for Inconel 718. Parameters such as flushing pressure, electrode material composition, and
tool electrode wear could be examined to further refine the machining process.

• Validation and Optimization of Machine Learning Models:

Further extend the present work by validating and optimizing the machine learning models developed for
predicting optimal EDM parameters. This could involve testing the models on larger datasets, incorporating
additional input variables, and refining the model architecture to improve prediction accuracy.

• Investigation of Hybrid Machining Approaches:

Extend the present work by investigating hybrid machining approaches that combine EDM with other
machining processes such as laser machining or abrasive water jet machining. Hybrid approaches could offer
synergistic benefits in terms of improved machining efficiency, surface quality, and tool life compared to
standalone EDM processes.

• Implementation of Real-Time Monitoring and Control Systems:

Further extend the present work by implementing real-time monitoring and control systems for adaptive EDM
machining. Advanced sensing technologies and control algorithms could be integrated into EDM
machines to continuously monitor process parameters and adjust machining conditions in real-time to
optimize performance and ensure consistent quality.

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 REFERENCES

1. Dr. Pal Pandian, Ivan Sunit Rout. "Parametric investigation of machining parameters in determining the
machinability of Inconel 718 using Taguchi technique and grey relational analysis" (2018).
2. Chinmaya P Mohanty, Siba Shankar Mahapatra, Manas Ranjan Singh. "An Experimental Investigation of
Machinability of Inconel 718 in Electrical Discharge Machining" (2014).
3. Fatlume Zhujani, Georgi Todorov, Konstantin Kamberov, Fitore Abdullahu. "Mathematical modeling and
optimization of machining parameters in CNC turning process of Inconel 718 using the Taguchi method"
(2013).
4. Ranjit Singh, Ravi Pratap Singh, Rajeev Trehan. "Machine learning algorithms based advanced optimization
of EDM parameters: An experimental investigation into shape memory alloys" (2022).
5. Uma Maheshwera Reddy Paturi, Vidhya Darshini B, N.S. Reddy. "Progress of machinability on the
machining of Inconel 718: A comprehensive review on the perception of cleaner machining" (2021).
6. R. Manikandan and R. Venkatesan. "Optimizing the machining parameters of Micro-EDM for Inconel 718"
(2012).

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 TIME SCHEDULE

SL.NO. TASK START DATE END DATE

1 IDEA GENERATION 1-10-2023 05-10-2023

2 FINDING SOLUTION 10-01-2024 20-01-2024

3 DESIGN AND MATERIAL SELECTION 21-01-2024 30-01-2024

4 FABRICATING 5-03-2024 10-03-2024

5 COMPLETION OF PROJECT 1-04-2024 10-04-2024

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THANK YOU