Investigation of material removal rate and surface roughness during wire electrical discharge machining (WEDM) of Inconel 625 super alloy by cryogenic treated tool electrode

The present investigation focuses the effect of process parameters on material removal rate (MRR) and surface roughness (Ra) in wire electric discharge machining of Inconel 625. Machining was done by using a normal zinc coated wire and cryogenic treated zinc coated wire. The experiments were performed by considering different process parameters viz. tool electrode, current intensity, pulse on time, pulse off time, wire feed and wire tension. The thickness of work material and dia. of wire are kept constant. Taguchi L18 (21 * 35) orthogonal array of experimental design is used to perform the experiments. Analysis of variance (ANOVA) is employed to optimize the material removal rate and surface roughness. Based on analysis it is found that pulse on time, tool electrode and current intensity are the significant parameters that affect the material removal rate and surface roughness. The scanning electron microscopy (SEM) are used to identify the microstructure of the machined work piece.