Influence of Novel Al-Ni Electrodes on Roughness and Machining Time in Inconel 625 EDM Machining: A Comprehensive RSM Performance Analysis

In the context of Inconel 625 machining, this study explores the effects of novel Al-Ni nano electrodes on surface roughness and machining time. Thorough performance study was undertaken to clarify the complex connections between the machining settings, electrode composition, and final surface quality. Important insights were obtained via methodical experimentation and data analysis, which helps optimize the machining procedures for improved productivity and surface quality when milling Inconel 625. This research presents an experimental investigation of the effects of the Electric Discharge Machining (EDM) input parameters, namely current, pulse-on time, and pulse-off time, on the surface roughness and machining time output parameters. Inconel 625 was the material of choice for the work piece. Electric discharge machining oil was used as the dielectric fluid and aluminium nanocomposite as the tool electrode. Response surface methodology (RSM) approach was employed in the experimentation. ANOVA was used to optimize the parameters and obtain the lowest possible surface roughness (SR) and machining time. The findings show that pulse-off time is the most significant motivating factor for SR. The current is the main determining factor for machining time. The Central Composite Design approach was used for optimization.