Development of Predictive Models and Prediction of Process Parameters for Wire Electrical Discharge Machining of Monel 400

The numerous applications and desirable attributes of Monel 400 urge many researchers to undertake multiple systematic evaluation studies for diverse manufacturing operations. Because of their exceptional mechanical qualities and great corrosion resistance, nickel-based alloys, particularly Monel 400, are increasing in popularity in a variety of applications. Because of their tendency for rapid work hardening and low thermal conductivity, these materials are particularly difficult to machine using traditional manufacturing techniques. Advanced material removal methodologies have been applied to eliminate such drawbacks and are regarded as a suitable alternative approach to traditional machining processes. Based on the Electrical Discharge Machining technique, Wire Electrical Discharge Machining was developed, which a sophisticated machining technology is used to machine hard materials with complex forms in any electrically conducting materials. The machinability performance of Monel 400 has been studied in this exploratory investigation by incorporating pulse on duration, pulse off duration, and applied current as independent factors at three levels. Using Taguchi's experimental design technique and an L27 Orthogonal array has been adopted for conducting experiments. Taguchi's single response analysis is used to examine the effect of process parameters on the intended output variables. Response factors considered in this study are Material Removal Rate, dimensional deviation and perpendicularity error. Empirical relationships are developed using multiple regression analysis and the developed equations are further used for predicting the desired performance. Taguchi-based Grey Relational Analysis (GRA) was employed to optimize the machining parameters. The findings of this study demonstrated that the suggested Taguchi-Grey approach is capable of enhancing the targeted performance measures in Wire Electrical Discharge Machining to achieve superior multiple performances.