An Experimental Study on the Nimonic-90 Superalloy using the WEDM Process

Abstract

Wire electro discharge machining (WEDM) is an uncommon machining technology that uses spark erosion to make complex forms out of a wide range of exotic materials, irrespective of their hardness. During Nimonic-90 WEDM, two response variables-rate of material removal (MRR) and surface roughness (SR)-were simulated together with five input process parameters: pulse on time (Ton), peak current (IP), wire tension (WT), pulse off time (Toff), and wire feed rate (WF). It is a nickel-base superalloy with high rupture strength at high temperatures and resistance to creep. The workpiece was cut using an electrode that was a 0.25 mm brass wire. A single-replicate L27 orthogonal array is employed for process optimization and regression model development, including process parameter–response parameter correlations.