Electrode Wear Rate Prediction Model for EDM Machined Inconel X750 by Response Surface Methodology Using Brass Electrode

Electrical discharge machining is basically a non-conventional material removal process which is widely used to produce dies, punches and moulds, finishing parts for aerospace and automotive industry. Inconel X-750, a high strength, age-hardenable, Ni-base super alloy, finds wide range of applications in aerospace engineering on the basis of its excellent high-temperature and cryogenic properties. This paper discusses the development of a mathematical model for electrical discharge machined inconel X750 metal by using response surface methodology. The electrode wear rate (EWR), model is developed in terms of Pulse peak current (Ip), Pulse on time (Ton), Gap voltage (V). The effect of these parameters over electrode wear rate is presented. The contour plots have been generated from the mathematical model. The model generated shows that the electrode wear rate increases with an increase of gapvoltage and dcreases with increase in pulse on time. Electrode wear rate increases when pulse peak current increases. The second order is more accurate based on the variance analysis and the predicted value is closer to the experimental result.