Inconel 718 is a nickel-rich superalloy that can function in cryogenic to
high-temperature applications. It has excellent mechanical and
corrosion-resistant properties. This research focuses on developing Cu and
Cu–alloy–tungsten disulfide (WS2) tools developed through a stir casting route,
and the machining behaviour of Inconel 718 alloy in the EDM Process is
investigated. The influence of output responses of Removal rate of material
(RRM), surface roughness (SR), and tool wear loss rate (TWR) on input
constraints pulse time-on, peak discharge current, and type of tool. The optimal
parameters are studied with the aid of the Response Surface Methodology (RSM)
and Analysis of Variance (ANOVA) combination, in response to maximize and
decrease the RRM, TWR, and SR, respectively. It is found that using the
Cu-WS2 tool provides an optimum finding with a peak discharge
current of 18 Amps, and pulse on time of 8 μs yields the best value for RRM,
TWR, and SR. In addition, a three-dimensional contour plot between the tool type
and process parameter's input and output values was obtained. Finally, the
confirmation test was conducted, and then it was compared with the experimental
and expected outcome. The optimal solution's minimum deviation reflects the
effectiveness of the optimized model.