Predictive Modelling and Process Parameter Prediction for Monel 400 Wire Electrical Discharge Machining for Rocket Frames

Due to their inherent properties and superior performance over titanium-based materials, nickel-based superalloys are widely utilized in the manufacturing industry. Monel 400 is among them. This nickel-copper alloy possesses exceptional corrosion resistance and mechanical properties. Monel 400 is primarily utilized in the chemical industry, heat exchangers, and turbine component manufacturing. Due to the properties of Monel 400, it is deemed as hard to machine materials with the aid of conventional methods. For investigating the performance of this process, a three-level analysis was carried out. Pulse on duration and applied current at three levels are the independent parameters used for designing the experiments. In this present article, a single-response analysis technique is used which is known as Taguchi to investigate the impact of the various process parameters on the output variables. They focused on three response factors namely the rate of material removal, deviation in the dimension, and perpendicularity error. An efficient predictive model has been developed with the help of regression analysis. To enhance the performance of Wire Electrical Discharge Machining (WEDM) process, Taguchi based grey approach has been adopted. The findings of the study revealed that the proposed approach could assist to enhance the overall effectiveness of the process.