Experimental Analysis on Wire Electrical Discharge Machining of Nickel Alloy Using Taguchi Based Grey Relational Analysis

Stellite is a nickel based superalloy and expansively adopted in higher temperature engineering applications. This alloy possesses better mechanical properties such as strength and hardness. Due to its lesser thermal conductivity, it is difficult to machine by conventional methods of machining. For avoiding such kind of demerits, advanced methods of machining have been introduced. Wire Electrical Discharge Machining (WEDM) is one of category of thermal energy based machining methods which is developed from the concept of Electrical Discharge Machining. This kind of machining method is preliminarily engaged for making complex shaped components especially in harder and electrically conductive materials. In this present experimental study, an endeavour has been taken to analyse the optimized process parameters for achieving better machining performance during WEDM of Stellite using Taguchi-Grey approach. The experimental runs are planned by Taguchi design approach and also the combination of input process variables is determined for accomplishing improved performance in machining. The significance of pulse on time, pulse off time and peak current on desired performance measures such as material removal rate and surface roughness are examined by ANOVA analysis. The prominence of input variables on desired performance measures are also disclosed by contour analysis. The results obtained with this exploration would be a support for the manufacturers to enhance the productivity and products quality.